Authors: Assistant Professor Sharad Nirgude, Shubham Gorade, Shraddha Sali, Diksha Dusane
Abstract: This study investigates the failure of a blanking die used to produce busbar connecting element parts on a mechanical press. During operation, the tool broke early than expected life. due to cracks. forming at the die center. This failure resulted in reduced production of the product. The analysis revealed high stress concentrations at the center of the die. These areas aim to identify the causes of the failure by studying the design closely and using finite element analysis with ANSYS software. A 3D model of the press tool was created by using NX software. The stress distribution is more where the cracks appeared in the failed tool. Poor clearance and design in the die increased these stress peaks. Recommendations are for improve press tool by adding same changes in design to reduce stress concentration, and improving material selection or heat treatment to improve toughness and fatigue resistance. That steps improve tool life, lower failure frequency, and enhance the reliability of busbar component element
