In India, there is an ever-increasing demand for two-wheelers which leads companies to plan for at least a couple of years to meet the demand and avoid losing any customers to competitors. When I was working as a student - engineer with Badve engineering our customer needed a new forming tool to produce more mufflers for their two-wheelers.
The production consisted of 4 steps of forming as shown below. The forming process is named OP-10 through 40 for reference. I designed the new tools based on the requirements, the new designs were promising and gave a product boost of 37%. The tool was future-proof and passed all the physical and computational tests.
The tools looked like the images below:
Forming Step 1
Forming Step 2
Forming Step 3
Forming Step 4