Investigation of the Micro Hardness at the Cut Surface of Fine Blanked Parts with Variation of Sheet Material and Cutting Temperature

2021 ◽  
Vol 883 ◽  
pp. 269-276
Author(s):  
Ingo Felix Weiser ◽  
Andreas Feuerhack ◽  
Thomas Bergs
Keyword(s):  
Sheet Material ◽  
Cutting Temperature ◽  
Micro Hardness ◽  
Functional Surface ◽  
Machining Processes ◽  
Forming Process ◽  
Fine Blanking ◽  
Cutting Surface ◽  
Blanking Process ◽  
Cut Surface

Fine blanking is a production technology of high importance especially for the automotive industry. As a procedure of sheet metal separation, it is possible to produce complex parts in a single stroke. As a difference to conventional punching, the cutting surface of fine blanked parts can often be used as a functional surface without further process steps. However, fine blanking as a forming process changes the microstructure of the metal sheet to a higher extend than cutting or machining processes. Due to this, it is of utmost importance to investigate the cause-effect-relations between the fine blanking process parameters and the resulting properties of the fine blanked part. Especially the condition of the cut surface as an important quality criterion has to be investigated. The quality characteristics of the cut surface of fine blanked parts are often subject of investigations. In addition, it would be of importance to investigate how the material properties in the shear zone are changed by the fine blanking process. This on one hand in turn can enable conclusions to be drawn about possible punch wear. If, on the other hand, hardening of the cut surface takes place as a result of fine blanking, then this could have a positive influence on the application properties of fine blanked components. Thus, an experimental fine blanking investigation of the micro hardness of the cutting surface has been made with variation of steel material and cutting temperature. It could be demonstrated that the micro hardness increases in direction towards the burr. This is independent on material and cutting temperature.

scholarly journals A Novel Force Variation Fine Blanking Process for the High-strength and Low-plasticity Material

2021 ◽  
Author(s):  
Huajie Mao ◽  
Han Chen ◽  
Yanxiong Liu ◽  
Kaisheng Ji
Keyword(s):  
Early Stage ◽  
Hydrostatic Stress ◽  
High Strength ◽  
Forming Force ◽  
Forming Process ◽  
Fine Blanking ◽  
Application Range ◽  
Cutting Surface ◽  
Force Variation ◽  
Blanking Process

Abstract Fine blanking is a kind of metal forming process with the advantages of high precision, good surface quality and low cost. Influenced by the concept of lightweight, a large number of metal materials with high strength are widely used in various fields. High strength materials are prone to be cracked during plastic deformation due to their poor plasticity, which limits the application range of them. This paper proposed a force variation fine blanking process for high-strength and low-plasticity materials. At the same time, a method to find the curve of forming force for this novel process was presented. A 2D finite element fine blanking model was established for the TC4 material. Combining genetic algorithm and neural network methods, a model was built up to find the optimal forming force loading curve. The parts fabricated by force variation loading and constant loading fine blanking process were compared through experiments. The mechanism of force variation fine blanking is also revealed. The forming force mainly affects the length of clean cutting surface by affecting hydrostatic stress. According to the ultimate optimal loading curve, the forming force should be kept at a low level in the early stage of blanking stroke, and increased gradually in the ending stage. In the application of force variation fine blanking, the part with long length of clean cutting surface can be obtained with lower die load.

Investigation on the Increasing Material Hardness on Fineblanked Sprocket

2009 ◽  
Vol 83-86 ◽  
pp. 1099-1106 ◽  
Author(s):  
Sutasn Thipprakmas ◽  
C. Chanchay ◽  
N. Hanwach ◽  
W. Wongjan ◽  
K. Vichitjarusgul
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Equal Channel Angular Extrusion ◽  
Grain Structure ◽  
Forming Process ◽  
Element Analysis ◽  
Fine Blanking ◽  
Material Hardness ◽  
Blanking Process ◽  
Cut Surface

In cold working metal forming process, severe plastic deformation results in changes in the material properties. Earlier researches mainly investigated the rolling and equal channel angular extrusion (ECAE) processes. This study focuses on the fine-blanking process, specially the increasing material hardness on the fineblanked sprocket part. The microstructure around the cut surface is observed and the finite element analysis is done to clarify the mechanism of the increasing hardness as well. The microstructure revealed increasingly compressed and elongated grain structure of the contributed grain flow and orientation, as the blankholder and counterpunch forces increased. This resulted in the increased material hardness around the cut surface. Thus, these results theoretically clarified the mechanism of the increasing material hardness in the fine-blanking process regarding microstructural evolution, with the associated finite element analysis. Therefore, the special characteristic features in the fine-blanking process, result in the pronounced hardening around the fineblanked surface.

A Study on the Clearance Decision of Fine Blanking Tool for Eco-Al Special Parts with Various Inner Corner Shapes

2013 ◽  
Vol 392 ◽  
pp. 31-35 ◽  
Author(s):  
Jong Deok Kim ◽  
Young Moo Heo ◽  
Si Tae Won
Keyword(s):  
Light Metal ◽  
Design Factor ◽  
Fine Blanking ◽  
Cutting Surface ◽  
Special Part ◽  
New Material ◽  
Automotive Parts ◽  
Shear Characteristics ◽  
Secondary Operations ◽  
Blanking Process

Fine blanking is a press-working process that permits the production of precise finished components which are cleanly sheared through the whole cutting surface. It can be eliminated secondary operations, such as milling, grinding, etc. Recently, many studies on the weight reduction of automobile for fuel saving were underway. Especially, there are many examples in which light metal like Al were applied for automotive parts. Eco-Al is the new material which is replaced Mg of aluminum alloy with Mg+Al2Ca, therefore Eco-Al material has improved mechanical properties and formability. The clearance between the punch and die of a fine blanking tool is an important design factor that affects the sheared surface of a product. In a fine blanking process, the clearance is typically assigned a 0.5% material thickness. If the clearance is too big, a fractured surface would occur in the product while if it is too small, bulging would occur. In this study, a setting for optimum clearance was proposed for inner corner shapes by checking shear characteristics and bulging effects according to various clearances. After designing a special part with various corner shapes possessing Eco-Al5052 (thickness: 4 mm), a fine blanking tool was constructed and fine blanking experiments were conducted. The result could be usefully applied in fine blanking processes for Eco-Al automobile parts with corner shapes in the future.

Numerical Simulation and Parameter Optimization of Cam’s Fine Blanking Process

2011 ◽  
Vol 396-398 ◽  
pp. 134-139
Author(s):  
An Long ◽  
Rui Ge ◽  
Yi Sheng Zhang ◽  
Li Bo Pan
Keyword(s):  
Numerical Simulation ◽  
Simulation Model ◽  
Parameter Optimization ◽  
Processing Parameters ◽  
Forming Process ◽  
Fine Blanking ◽  
3D Software ◽  
Blanking Process ◽  
Deform 3D

To conclude the mechanics of fine blanking, the numerical simulation model of a cam’s fine blanking process was established, the forming process was simulated by DEFORM-3D software, the deform principle was summarized. Then the effect of three key processing parameters such as gap between punch and die, pressure-pad-force/counter force, serrated ring postion to fine blanking quality were researched, optimized parameters in fine blanking were gained.

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.

Parameters Design of Discontinuous Dot Indenter in Fine Blanking Process with Different Thickness Workpiece

2016 ◽  
Vol 716 ◽  
pp. 762-769 ◽  
Author(s):  
Fei Zhou ◽  
Hua Jie Mao ◽  
Yan Xiong Liu ◽  
Lin Hua
Keyword(s):  
Orthogonal Experiment ◽  
Machining Accuracy ◽  
Surface Zone ◽  
Fine Blanking ◽  
Element Simulation ◽  
The Cost ◽  
Blanking Process ◽  
The Relationship ◽  
Cut Surface ◽  
Different Thickness

This paper proposes a new blankholder to fine blanking process. V-ring indenter has been widely applied in fine blanking to produce clean cut parts, however, it is difficult to be manufactured, the machining accuracy of which is hard to ensure and the cost is very high. In this approach, the fine blanking process combined with discontinuous dot indenter was put forward and the parameters design for workpiece with different thickness was studied with the finite element simulation and the orthogonal experiment methods. The larger burnished surface zone can be obtained by optimizing discontinuous dot indenter parameters. In addition, the relationship between the discontinuous dot indenter parameters and the workpiece thickness was got from data processing. Finally, applying this relationship to fine blank workpiece with different thickness, nearly full clean cut surface part was obtained.

scholarly journals Analysis of Shear Droop on Cut Surface of High-Tensile-Strength Steel in Fine-Blanking Process

2011 ◽  
Vol 52 (3) ◽  
pp. 447-451 ◽  
Author(s):  
Toru Tanaka ◽  
Seiya Hagihara ◽  
Yuichi Tadano ◽  
Shuuhei Yoshimura ◽  
Takuma Inada ◽  
...  
Keyword(s):  
Tensile Strength ◽  
High Tensile Strength ◽  
Fine Blanking ◽  
Blanking Process ◽  
Cut Surface

scholarly journals Optimum Clearance in the Microblanking of Thin Foil of Austenitic Stainless Steel JIS SUS304 Studied from Shear Cut Surface and Punch Load

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 678 ◽  
Author(s):  
Yohei Suzuki ◽  
Ming Yang ◽  
Masao Murakawa
Keyword(s):  
Stainless Steel ◽  
Fracture Criterion ◽  
Hydrostatic Stress ◽  
Thin Foil ◽  
Finite Element Analyses ◽  
Fine Blanking ◽  
Punch Load ◽  
Negative Clearance ◽  
Blanking Process ◽  
Cut Surface

An extrusion-type fine blanking with a negative clearance was proposed by the authors instead of standard fine blanking for creating a full-sheared surface in the micro blanking process. In this study, micro blanking experiments and finite element analyses with narrow, zero and negative clearances are carried out for the optimizing the clearance at which a shear cut surface can be finished with a full-sheared surface with the minimized punch load. Fracture criterion, hydrostatic stress and maximum punch stress for the conditions with various clearances are investigated. As a result, it was clarified that the clearance at which the cut surface does not fracture and minimization of the punch load is achieved is gained by the use of clearance −4 μm.

scholarly journals Active vibration control of mechanical servo high speed fine-blanking press

2020 ◽  
Author(s):  
Yan xiong Liu ◽  
Yuwen Shu ◽  
Wen tao Hu ◽  
Xin hao Zhao ◽  
Zhi cheng Xu
Keyword(s):  
Vibration Control ◽  
Mechanical Model ◽  
High Speed ◽  
Active Vibration Control ◽  
Vibration Measurement ◽  
Machining Accuracy ◽  
Forming Process ◽  
Fine Blanking ◽  
Active Vibration ◽  
Blanking Process

Abstract The fine-blanking process as an advanced sheet metal forming process has been widely applied in the industrial area. However, special designed equipment is required for this process. In this paper, a novel mechanical servo high speed fine-blanking press with the capacity of 3200kN is proposed, and the vibration control for this machine is researched to achieve the requirement of fine-blanked parts of high dimensional accuracy, since the vibration of the fine-blanking machine will cause the machining displacement error and reduce the machining accuracy. The self-adaptive feed forward control is used to simulate the active vibration control of the mechanical fine-blanking machine. The vibration control principle of the fine-blanking machine is described and the control algorithm is established. At the same time, the vibration mechanical model of the fine-blanking machine as the controlled object is established, and the parameters of the excitation input and the mechanical model are obtained by the fine-blanking finite element simulation and the experiments of the vibration measurement of the press. Finally, the numerical simulation and analysis of active vibration control based on Matlab are carried out. The results show that the control effect is good, and the vibration response is effectively reduced.

scholarly journals Active Vibration Control of a Mechanical Servo High-speed Fine-Blanking Press

2021 ◽  
Vol 67 (9) ◽  
pp. 445-457
Author(s):  
Yanxiong Liu ◽  
Yuwen Shu ◽  
Wentao Hu ◽  
Xinhao Zhao ◽  
Zhicheng Xu
Keyword(s):  
Vibration Control ◽  
High Speed ◽  
Active Vibration Control ◽  
Vibration Measurement ◽  
Machining Accuracy ◽  
Control Effect ◽  
Forming Process ◽  
Fine Blanking ◽  
Active Vibration ◽  
Blanking Process

The fine-blanking process as an advanced sheet metal forming process has been widely applied in industry. However, specially designed equipment is required for this process. In this paper, a novel mechanical servo high-speed fine-blanking press with the capacity of 3200 kN is proposed, and the vibration control for this machine is researched to achieve the requirement of fine-blanked parts of high dimensional accuracy, since the vibration of the fine-blanking machine will cause the machining displacement error and reduce the machining accuracy. Self-adaptive feed-forward control is used to simulate the active vibration control of the mechanical fine-blanking machine. The vibration control principle of the fine-blanking machine is described, and the control algorithm is established. At the same time, the mechanical vibration model of the fine-blanking machine as the controlled object is established, and the parameters of the excitation input and the mechanical model are obtained by the fine-blanking finite element simulation and the experiments of the vibration measurement of the press. Finally, the numerical simulation and analysis of active vibration control based on MATLAB are carried out. The results show that the control effect is good, and the vibration response is effectively reduced, thus greatly increasing the processing accuracy, saving a significant amount of energy, and reducing the energy consumption and defective rate.

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