Design and finite element analysis of innovative tooling elements (stress pins) to prolong die life and improve dimensional tolerances in precision forming processes

The use of stress pins as an innovative pre-stressing element was discussed. The results of a design methodology investigation through combined finite element analysis and design of experiment studies for large and non-axisymmetric precision forming tooling were presented. Smart pre-stressing elements were implemented to overcome very fundamental and practical problem of prolonging the die life, preventing die failures and improving dimensional part tolerances by applying local and controlled pre-stressing effects.