Optimization of Sheet Metal Operation Die through Stage Reduction Techniques

Traditionally, automotive sheet metal panel manufacturing requires multiple sequential die operations, typically OP10 (drawing), OP20 (trimming), OP30 (restriking), and OP40 (piercing), to achieve the required geometry, dimensional accuracy, and surface quality. This project focuses on the design and development of an integrated sheet metal operation die that combines the OP30 (restriking) and OP40 (piercing) stages into a single multifunctional die, while retaining the existing OP10 draw die and OP20 trim die configurations. The proposed die incorporates advanced cam-driven mechanisms to enable complex geometric refinements and synchronized piercing actions. Additionally, dedicated scrap-cutting and evacuation systems are implemented to prevent scrap interference and surface contamination during simultaneous restriking, trimming, and piercing operations. Experimental validation demonstrates that consolidating OP30 and OP40 eliminates one press operation and intermediate material transfer, resulting in a reduced production cycle time per panel. The integrated die approach also reduces tooling inventory, press setup time, and overall manufacturing cost, while consistently maintaining tight dimensional tolerances. This study addresses key engineering challenges in multi-operation die integration and presents an effective strategy for stage reduction and productivity enhancement in automotive panel manufacturing.