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