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Sheet metal components frequently are used in industry. There are several methods to produce them. Progressive die one of the most widely applied devices to sheet metal components manufacturing. The progressive dies reduce the time and cost of producing complex sheet metal components. However, the design and manufacture of these dies are difficult. CAD/CAM systems have been proved to be very useful tools for this task. In this paper, two the important stages of die design process, Nesting and Piloting system are studied. By using fuzzy set theory and three fuzzy rules: scrap percentage, type of pilots, distance between pilots, the optimum state of nesting and piloting is determined. These rules are applied according to expert comments and industrial observations. According to our investigation, piloting accuracy impresses the final nesting design, thus a new fuzzy rule based on distance between pilots is proposed in this paper. The presented method is based on algebra algorithm that it determines suitable and exact place of semi-direct and indirect pilots and decrease calculation time. Three components taken from industry and previous papers are used to show the capability of the proposed method.

Keywords: Progressive Die, Nesting, Piloting, Computer Aided Design, Fuzzy set Theory

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