The competition between firms manufacturing automobile fasteners has become fiercely competitive due to the influence of the American automobile crisis. This thesis is written for the general manager of Funda Fastners Co Ltd to provide a solution for saving costs on tooling, thereby remaining competitive in the industry and boosting profits to desired levels.
A bolt used for assembling engines is formed by a “2 die 2 blow” process. The Torx punch, used in the process of the second blow, fails regularly after 2000 operations. To examine the cause for this unanticipated and quick failure, the forming process was modelled in a 3D environment using a finite element program called Abaqus.
Due to time constraints and unforseen problems during the modelling process, the model for investigating the problem could not be solved and the required results could not be obtained.
On the other hand, the methodology in this thesis provides full details of the modelling process and can certainly be used as a manual for the student who desires to complete the remaining work, or as a reference for student who desires to model a 3D problem using Abaqus.