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

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.

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

Materials Science Forum ◽

10.4028/www.scientific.net/msf.575-578.316 ◽

2008 ◽

Vol 575-578 ◽

pp. 316-321 ◽

Cited By ~ 13

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 ◽

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.

The Optimized Negative Clearance Value with Reason in ASTM-Gr.D Fine-Blanking with Negative Clearance Blanking

10.4028/www.scientific.net/amr.588-589.80 ◽

2012 ◽

Vol 588-589 ◽

pp. 80-83

Author(s):

W.F. Fan ◽

J.H. Li ◽

F. Li

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Similarity Theory ◽

Element Model ◽

Analysis Software ◽

Rigid Plastic ◽

Element Analysis ◽

Fine Blanking ◽

Geometry Model ◽

Negative Clearance

This paper has established geometry model of the rigid-plastic Finite Element Model (FEM) basing on the foundation of similarity theory. It has simulated and analyzed the material of ASTM-Gr.D used by finite element analysis software of metal plastic DEFORM with different negative clearance values blanking, which obtains the caver of the different negative clearance values with roll-over with sheared zone with punching load. According to the result of simulation, it has made an experiment on the ASTM-Gr.D of 2.0(mm) thickness with the different negative clearance, and obtained samples with sheared well and no burr, which summarized that it could achieve no burr in fine blanking when the values of negative clearances value took -0.1 ~ -0.3mm.

Comparative Analysis the Stainless Steel Surface Structure on Fine-Blanking with Negative Clearance and Common Blanking

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.229-231.105 ◽

2012 ◽

Vol 229-231 ◽

pp. 105-108

Author(s):

H. Du ◽

F. Li ◽

H. Zhang

Keyword(s):

Stainless Steel ◽

Fracture Surface ◽

Work Hardening ◽

Stainless Steel Surface ◽

Fine Blanking ◽

Material Fracture ◽

Negative Clearance ◽

Blanking Process ◽

Positive Effect

The stainless steels are used more and more in blanking process. To further enhance the quality of blanking fracture surface, this paper made the related experiments of fine-blanking with negative clearance in stainless steel. Through the comparison analysis between the fine-blanking microstructure and common blanking one with stainless steel, the result points out that the fine-blanking with negative clearance inhibit the warping in common blanking, make the work-hardening of material fracture surface improves, and which can have a more positive effect for the fine-blanking with negative clearance. Meanwhile, the work-hardening capacity of two blanking methods was different, and it can enhance the punching section entire strength commendably by fine blanking with negative clearance.

Modelling of Fine Blanking Process of the Aluminium Sheets

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.473.290 ◽

2011 ◽

Vol 473 ◽

pp. 290-297 ◽

Cited By ~ 5

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.

Study on Work Hardening Performance of Pure Shearing Fine-Blanking with Negative Clearance for ASTM-Gr.D and ASTM-1022 Steel

10.4028/www.scientific.net/amr.97-101.145 ◽

2010 ◽

Vol 97-101 ◽

pp. 145-148

Author(s):

J.H. Li ◽

W.F. Fan ◽

Zhong Mei Zhang

Keyword(s):

Work Hardening ◽

Work Piece ◽

Micro Hardness ◽

Fine Blanking ◽

Negative Clearance ◽

Distribution Of Stress ◽

Improve Fatigue Strength ◽

Important Significance ◽

Improve Fatigue

In the process of blanking, the work hardening capability of material possesses very important significance. It not only affects the internal stress value of distorting material, the distribution of stress and the value of blanking force, but also blanking deforming limit and quality of blanked work piece. This paper carries through pure shearing fine-blanking processing experiment with negative clearance for the ASTM-Gr.D and ASTM-1022 steel as well as the micro hardness of the sheared surface for the blanked work pieces in breadthways and lengthways direction measured by Vickers-micro hardness instrument (MH-6). Mechanism of work hardening for fine-blanking with negative clearance is discussed. Meanwhile, the work hardening capability of blanked work piece is analyzed. The work hardening degree of the materials possessing different hardening index is compared. It could be concluded that the work hardening degree of the blanking work pieces was strengthened evidently by the fine-blanking with negative clearance. The hardening layer of blanking fracture could enhance structure intensity and wear resistance of blanking work piece evidently. Therefore, it could improve fatigue strength and the working life of work piece greatly.

Research on Fine Blanking Process with Stepped-Edge Punch

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.16-19.495 ◽

2009 ◽

Vol 16-19 ◽

pp. 495-499 ◽

Cited By ~ 3

Author(s):

Si Ji Qin ◽

Li Yang ◽

Jia Geng Peng

Keyword(s):

Finite Element Method ◽

Finite Element Analysis ◽

Finite Element ◽

Hydrostatic Stress ◽

Element Analysis ◽

Fine Blanking ◽

Q235 Steel ◽

Negative Clearance ◽

Blanking Process ◽

Industrial Aluminum

The fine blanking process with a stepped-edge punch was researched by finite element method (FEM) and experiment investigation. Finite element analysis showed that the hydrostatic stress of the blank around the edges changes a little during fine blanking process using a stepped-edge punch with negative clearance. The burnish zone of sheared surface increases with the increase of the relative negative clearance. The reasonable forming parameters were presented by a lot of experiment investigations. Parts of three kinds of materials, Q235 steel, copper and industrial aluminum, were formed using fine blanking process with a stepped-edge punch. Full burnish zone were obsearved for all the parts.

Qualitative Analysis and Study the Workpiece Shearing Surface Quality of Fine-Blanking with Negative Clearance

Materials Science Forum ◽

10.4028/www.scientific.net/msf.697-698.371 ◽

2011 ◽

Vol 697-698 ◽

pp. 371-376

Author(s):

Hong Du ◽

Zhong Mei Zhang

Keyword(s):

Electron Microscope ◽

Scanning Electron Microscope ◽

Qualitative Analysis ◽

Surface Quality ◽

Reference Value ◽

Quality Standard ◽

Fine Blanking ◽

Negative Clearance ◽

Scanning Electron

The workpieces of fine blanking with negative clearance were obtained through the fine-blanking with negative clearance processing experiment. The fractography photographs of workpieces shearing surface were scanned by scanning electron microscope (SEM), and the characterization parameters and quality standard of workpieces shearing surface with negative clearance were analyzed in the processing of blanking. According to the characterization parameters and quality standard of workpieces shearing surface with negative clearance, the workpiece with the length ratio of burnish band, deflection error, rollover error and blanking burr were analyzed qualitative. The findings have a certain reference value to the blanking related profession.

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

Materials ◽

10.3390/ma13030678 ◽

2020 ◽

Vol 13 (3) ◽

pp. 678 ◽

Cited By ~ 3

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.

An Innovative Experimental Setup for Laboratory Tests of Fine Blanking Process

10.4028/www.scientific.net/amr.650.567 ◽

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 ◽

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.

Comparative Study of the Process Fracture between Fine-Blanking with Negative Clearance and Conventional Blanking

10.4028/www.scientific.net/amr.97-101.191 ◽

2010 ◽

Vol 97-101 ◽

pp. 191-194 ◽

Cited By ~ 3

Author(s):

Hong Du ◽

Wei Fu Fan ◽

Zhong Mei Zhang

Keyword(s):

Smooth Surface ◽

Work Piece ◽

Separation Mechanism ◽

Final Phase ◽

Fine Blanking ◽

Aisi 1045 Steel ◽

Aisi 1045 ◽

Negative Clearance ◽

1045 Steel ◽

The different separation mechanism of fine-blanking with negative clearance and conventional blanking under different blanking process are analyzed through fine-blanking with negative clearance and conventional blanking processing experiments on AISI-1045 steel. The fractography photographs in the different deformation regions, such as rollover zone, shearing band, fracture zone and burr zone are scanned by scanning electron microscope (SEM-JSM-6360LV). The place of fracture of fine-blanking with negative clearance has emerged into the middle of work piece not the undermost of workpiece, and the width of fracture band is as tiny as 50-100 micron. The smooth surface formed by the uniform plastic flow in the process fine-blanking with negative clearance, and the full course of finally toughness fracture have been analyzed in the final phase of ejecting in fine-blanking with negative clearance. From the perspective of material meso-damage, the fracture mechanism of special blanking process with negative clearance has been illustrated in details.