Research on the Shrinkage Cavity Defect of the Extruded Boss in Fine Blanking Process

2011 ◽  
Vol 314-316 ◽  
pp. 695-702
Author(s):  
Jian Lan ◽  
Yong Zhang ◽  
Chang Peng Song ◽  
Lin Hua
Keyword(s):  
Material Flow ◽  
Metal Flow ◽  
Sheet Thickness ◽  
Shrinkage Cavity ◽  
Fine Blanking ◽  
Blank Holder ◽  
Shrinkage Cavities ◽  
Blanking Process ◽  
First Time

The shrinkage cavity defect of the extruded boss is harmful to the quality of fine blanking workpiece and process. To suppress the shrinkage cavity defect, firstly, the boss extrusion is simulated to analyze main features of metal flow and the causes of the shrinkage cavity defects; secondly, some parameters affecting the material flow, such as the size of die and punch, blank holder force, friction coefficient, sheet thickness and counter force, are studied to figure out their influences on the depth of shrinkage cavities respectively; finally, the process parameters of a special workpiece are selected according to research results above, and experiment verified that the selected parameters can suppress the shrinkage cavity defect pertinently. In the paper, the shrinkage cavity defect is systematically studied for the first time, and this provides the base to design and optimize the extruded boss feature in fine blanking process.

scholarly journals Effect of Tool Geometry Parameters on the Formability of a Camera Cover in the Deep Drawing Process

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3993
Author(s):  
Thanh Trung Do ◽  
Pham Son Minh ◽  
Nhan Le
Keyword(s):  
Deep Drawing ◽  
Thickness Distribution ◽  
Metal Flow ◽  
Sheet Thickness ◽  
Side Wall ◽  
Tool Geometry ◽  
Drawing Process ◽  
Nose Radius ◽  
Deep Drawing Process

The formability of the drawn part in the deep drawing process depends not only on the material properties, but also on the equipment used, metal flow control and tool parameters. The most common defects can be the thickening, stretching and splitting. However, the optimization of tools including the die and punch parameters leads to a reduction of the defects and improves the quality of the products. In this paper, the formability of the camera cover by aluminum alloy A1050 in the deep drawing process was examined relating to the tool geometry parameters based on numerical and experimental analyses. The results showed that the thickness was the smallest and the stress was the highest at one of the bottom corners where the biaxial stretching was the predominant mode of deformation. The problems of the thickening at the flange area, the stretching at the side wall and the splitting at the bottom corners could be prevented when the tool parameters were optimized that related to the thickness and stress. It was clear that the optimal thickness distribution of the camera cover was obtained by the design of tools with the best values—with the die edge radius 10 times, the pocket radius on the bottom of the die 5 times, and the punch nose radius 2.5 times the sheet thickness. Additionally, the quality of the camera cover was improved with a maximum thinning of 25% experimentally, and it was within the suggested maximum allowable thickness reduction of 45% for various industrial applications after optimizing the tool geometry parameters in the deep drawing process.

The Contrast Research of the Finite Element Simulation for Ordinary and Fine Blanking with Negative Clearance

2008 ◽  
Vol 575-578 ◽  
pp. 316-321 ◽  
Author(s):  
H. Du ◽  
S.M. Ding
Keyword(s):  
Experimental Data ◽  
Reference Value ◽  
Engineering Practice ◽  
Fine Blanking ◽  
Equipment Investment ◽  
Element Simulation ◽  
Negative Clearance ◽  
Material Energy ◽  
Blanking Process

This paper puts forward a negative clearance fine-blanking theory and its technique process, and introduces the technical processing of fine-blanking which can be used on ordinary punching machines. In this paper, computer simulation and the experimental study of negative clearance fine-blanking process are carried out. Thus the parameters of the force of blanking, the value of negative clearance are determined. The effect of fine-blanking quality was obtained, and the perfect rate of the blanking fracture achieves 90%. By comparing negative clearance precise blanking with conventional blanking, the following conclusions are drawn: 1. Blanking quality of negative clearance blanking is increased by 57% than that of conventional blanking. 2. The down surface of the work-pieces obtained by the conventional blanking processing have 0.2 - 0.5 mm longitudinal burrs, while the work-pieces obtained by the negative clearance blanking have no burrs. Thus the processing of clear away the burrs could be spared. And the manpower, the material, energy and the equipment investment are saved. The researching result provides theoretic reference and the experimental data for the engineering practice. It has instructive significance and reference value to engineering manufacturing.

Modelling of Fine Blanking Process of the Aluminium Sheets

2011 ◽  
Vol 473 ◽  
pp. 290-297 ◽  
Author(s):  
Wojciech Wieckowski ◽  
Piotr Lacki ◽  
Janina Adamus
Keyword(s):  
Dimensional Accuracy ◽  
Soft Materials ◽  
Fine Blanking ◽  
Technological Quality ◽  
Aluminium Sheets ◽  
The Impact ◽  
Blanking Process ◽  
Cut Surface ◽  
Stress And Strain Distribution

The required technological quality of the blanked products can be achieved through operations of fine blanking. This allows for obtaining products with improved dimensional accuracy and good quality cut-surface. In order to cut products from soft materials, including aluminium and its alloys, the methods of fine blanking with upsetting and fine blanking with reduced clearance are typically employed. The study presents the results of numerical modelling of the fine blanking process for a disk made of 1-millimetre sheet aluminium EN AW-1070A. The goal of the numerical simulations was to evaluate the effect of clearance between blanking die and the punch, and the impact of V-ring indenter on stress and strain distribution in the shearing zone.

Active Material Flow Control during High-Pressure Sheet Metal Forming

2005 ◽  
Vol 6-8 ◽  
pp. 377-384 ◽  
Author(s):  
Peter Groche ◽  
C. Metz
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Material Flow ◽  
High Pressures ◽  
Active Material ◽  
Sheet Thickness ◽  
Blank Holder ◽  
Rotationally Symmetric ◽  
Material Flow Control

During forming of non-rotationally symmetric sheet metal parts at high pressures nonuniform deformation conditions arise in the flange area. These deformations vary in height and consequently lead to heterogeneous sheet thickness distributions. When using semi-rigid tools, high clamping forces are necessary in order to compensate for the developing sheet thickness variations in the flange area and to avoid leakages of the system or wrinkling. Moreover, the heterogeneous distribution of the clamping force is strengthened by press inaccuracies. This results in a higher surface pressure distribution on one side of the flange and finally in a non-uniform material flow out of the flange area. The development of a segmented active-elastic blank holder enables an active material flow control of the flange movement during sheet metal forming at high pressures. The local elasticity of the active-elastic blank holder is based on an optimized layout of the local tool rigidity. For this purpose, different grooves were integrated below the blank holder surface. This paper provides an overview of the developed technology, advantages with regard to the part’s quality, and recent results comparing the production of non-rotationally symmetric parts with segmented active-elastic tools vs. semi-rigid tools.

An Innovative Experimental Setup for Laboratory Tests of Fine Blanking Process

2013 ◽  
Vol 650 ◽  
pp. 567-571
Author(s):  
M. Shahsavan ◽  
M. Sedighi
Keyword(s):  
Cutting Edge ◽  
Test Rig ◽  
Main Concept ◽  
Punch Force ◽  
Fine Blanking ◽  
Manual Adjustment ◽  
Innovative Idea ◽  
Steel Aisi ◽  
Blanking Process

Fine blanking process can produce parts with accurate cutting edge quality. Studying the effects of process parameters on accuracy and quality of fine banking products are usually expensive. In this paper, an innovative idea has been introduced for a set of fine blanking test rig which is not as complicate and expensive as standard fine blanking dies but it could be used alternatively for limited laboratory works. The main concept of the rig is based on manual adjustment of counter punch force and blank holder force by means of rubber spring and torque meters respectively. As a case study, the effect of counter punch force of fine blanking process in a 2mm thickness steel AISI-1006 sheet was studied by this test rig. The results show that increasing the counter punch force makes burr dimension on cutting edge to get smaller which means better quality of the product.

Numerical Investigation of Fine Blanking of a Helical Gear

2012 ◽  
Vol 190-191 ◽  
pp. 121-125 ◽  
Author(s):  
Shan Yang ◽  
Lin Hua ◽  
Yan Li Song
Keyword(s):  
Effective Strain ◽  
Metal Flow ◽  
Three Dimensional ◽  
Helical Gear ◽  
Fe Model ◽  
Forming Process ◽  
Rigid Plastic ◽  
Fine Blanking ◽  
Metal Forming Process ◽  
Blanking Process

Fine blanking, as an effective and economy metal forming process, can be used for the manufacturing of helical gears with inclined forming movement. In the present study, a reliable three-dimensional (3D) rigid-plastic finite element (FE) model is developed on the DEFORM-3D platform for rotational fine blanking of a helical gear. Based on this FE model, distributions of different field variables such as metal flow velocity, mean stress and effective strain are obtained, and cut surface features and punch stroke curve are predicted. The results achieved in this study can not only evaluate the capabilities of the rotational fine blanking process of a helical gear, but also provide valuable guidelines and a better understanding of the deformation mechanism of this process.

Influence of Technological Parameters on Sheet Metal Punching Section Quality

2013 ◽  
Vol 734-737 ◽  
pp. 2488-2491
Author(s):  
Xian Chang Mao ◽  
Zheng Mei ◽  
Ren Yi Liu ◽  
Dai Song Luo
Keyword(s):  
Sheet Metal ◽  
Metal Cutting ◽  
Geometrical Parameters ◽  
Technological Parameters ◽  
Blank Holder ◽  
Current Trends ◽  
Jacking Force ◽  
Sheet Metal Cutting ◽  
Blanking Process

The section quality of sheet metal is influenced greatly by technological parameters during the blanking process, and it is valuable to research them. Base on the current trends and development of the sheet metal blanking, the technological parameters which influence the cutting face quality of blanking are introduced in detail, including blank holder force, Jacking force, mould structure and geometrical parameters, elastic medium, blanking speed, etc. The result shows that sheet metal cutting face quality of blanking can be improve effectively by reasonable parameters.

Fine Blanking Technology Optimization of Front End Cover of Timing System for Compressed

2016 ◽  
Vol 872 ◽  
pp. 67-72 ◽  
Author(s):  
Xin Yu Li ◽  
Chun Dong Zhu ◽  
Yan Chang Zhu
Keyword(s):  
Process Parameters ◽  
Efficient Operation ◽  
Fine Blanking ◽  
Front Cover ◽  
Finite Element Software ◽  
System A ◽  
Timing System ◽  
New Type ◽  
Blanking Process

Front cover is an important part of the car timing system, it is also an important parts of the engine to ensure the smooth flow.The quality of end cap is directly related to the normal and efficient operation of the engine.In this paper, through the research of the fine blanking process of the front cover of the timing system, a new type of fine blanking die is designed to improve the service life of the die and its parts.The influence rules of the process parameters such as the back top force, the counter pressure and the corner radius on punching smooth zone and the life of the mold, are analyzed by using the finite element software and a series of optimized process parameters are obtained after this.

Investigation Mechanism of V-Ring Indenter Geometry in Fine-Blanking Process

2009 ◽  
Vol 410-411 ◽  
pp. 305-312 ◽  
Author(s):  
Sutasn Thipprakmas ◽  
Masahiko Jin
Keyword(s):  
Hydrostatic Pressure ◽  
Material Flow ◽  
Crack Formation ◽  
Fem Simulation ◽  
Great Difficulty ◽  
The Finite Element Method ◽  
Fine Blanking ◽  
Simulation Results ◽  
Blanking Process ◽  
Indenter Geometry

The V-ring indenter geometry (angle, height and position) was investigated by using the finite element method (FEM) to theoretically clarify the mechanism and its action in the fine-blanking process. The FEM simulation results indicate that very small or very large V-ring indenter angles, heights, and positions cause difficulty in the rotation of the material-flow and that the hydrostatic pressure is generated with great difficulty in the blanked material; therefore, crack formation occurs easily. The application of a suitable V-ring indenter angle, height, and position significantly suppresses the formation of rotating flow, which results in increased hydrostatic pressure, and crack formation is consequently prevented.

Study on Multi-Factor Blanking Parameters for Fine-Blanking with Negative Clearance through Simulation Optimization

2011 ◽  
Vol 697-698 ◽  
pp. 377-382
Author(s):  
J.H. Li ◽  
Zhong Mei Zhang
Keyword(s):  
Simulation Optimization ◽  
Quality Analysis ◽  
Analysis Software ◽  
Fine Blanking ◽  
Geometry Model ◽  
Plastic Analysis ◽  
Regress Analysis ◽  
Negative Clearance ◽  
Blanking Process

The plastic analysis software DEFORM was used to simulate the blanking process of metal plastic without burr. Based on theory of the rigid FEM, the geometry model used for blanking with a negative clearance was established. The facts of influence the quality of the blanking work pieces were analyzed and concluded, at the same time, the parameters were indicated to improve the quality of the blanking work pieces. Through the experiment, the blanking load was measured with different clearance, thickness and material in group. The reciprocity between these facts was analyzed and the clearance was optimized. After the blanking load was regress analysis, the coefficient of the load and these facts were researched. Using quality analysis of the work pieces in the experiment, the thickness and the material were obtained which were suitable for blanking of metal plastic without burr. The reactions which were used to separate the metal were studied, which offered thereunder for proper remaining based on the better quality and smaller blanking load.

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