scholarly journals Numerical simulation and optimization of fine-blanking process for copper alloy sheet

2021 ◽  
Author(s):  
Chun-Chih Kuo ◽  
Kuo-Wang Liu ◽  
Tse-Chang Li ◽  
Dai-You Wu ◽  
Bor-Tsuen Lin
Keyword(s):  
Fracture Zone ◽  
Punch Force ◽  
Fine Blanking ◽  
Blank Holder ◽  
Zone Width ◽  
Optimal Value ◽  
Quality Objective ◽  
Zone Depth ◽  
Die Roll ◽  
Blanking Process

AbstractWhen the fine-blanking process is used, secondary grinding or processing can be omitted because the shear surface of fine-blanking parts can achieve almost zero fracture zone requirements. The primary objective of the fine-blanking process is to reduce the fracture zone depth and die roll zone width. This study used a 2.5-mm-thick central processing unit (CPU) thermal heat spreader as an example. Finite element analysis software was employed to simulate and optimize the main eight process parameters that affect the fracture zone depth and die roll zone width after fine-blanking: the V-ring shape angle, V-ring height of the blank holder, V-ring height of the cavity, V-ring position, blank holder force, counter punch force, die clearance, and blanking velocity. Simulation analysis was conducted using the L18 (21 × 37) Taguchi orthogonal array experimental combination. The simulation results of the fracture zone depth and die roll zone width were optimized and analyzed as quality objectives using Taguchi’s smaller-the-better design. The analysis results revealed that with fracture zone depth as the quality objective, 0.164 mm was the optimal value, and counter punch force made the largest contribution of 25.89%. In addition, with die roll zone width as the quality objective, the optimal value was 1.274 mm, and V-ring height of the cavity made the largest contribution of 29.45%. Subsequently, this study selected fracture zone depth and die roll zone width as multicriteria quality objectives and used the robust multicriteria optimal approach and Pareto-optimal solutions to perform multicriteria optimization analysis. The results met the industry’s fraction zone depth standard (below 12% of blank thickness) and achieved a smaller die roll zone width.

scholarly journals Numerical Simulation and Optimization of Fine-Blanking Process for Copper Alloy Sheet

2021 ◽  
Author(s):  
Chun-Chih Kuo ◽  
Kuo-Wang Liu ◽  
Tse-Chang Li ◽  
Dai-You Wu ◽  
Bor-Tsuen Lin
Keyword(s):  
Fracture Zone ◽  
Punch Force ◽  
Fine Blanking ◽  
Blank Holder ◽  
Zone Width ◽  
Optimal Value ◽  
Quality Objective ◽  
Zone Depth ◽  
Die Roll ◽  
Blanking Process

Abstract When the fine-blanking process is used, secondary grinding or processing can be omitted because the shear surface of fine-blanking parts can achieve almost zero fracture zone requirements. Fine-blanking has the advantages of high precision and high production efficiency. It was originally used on watch parts, but with increasingly refined technology, it has been widely applied in computers, consumer electronics, communication products, and vehicle parts. The primary objective of the fine-blanking process is to reduce the fracture zone depth and die roll zone width. This study used a 2.5mm thick central processing unit (CPU) thermal heat spreader as an example. Finite element analysis software was employed to simulate and optimize the main eight process parameters that affect the fracture zone depth and die roll zone width after fine-blanking: the V-ring shape angle, V-ring height of the blank holder, V-ring height of the cavity, V-ring position, blank holder force, counter punch force, die clearance, and blanking velocity. Simulation analysis was conducted using the L18 (21×37) Taguchi orthogonal array experimental combination. The simulation results of the fracture zone depth and die roll zone width were optimized and analyzed as quality objectives using Taguchi’s smaller-the-better design. The analysis results revealed that with fracture zone depth as the quality objective, 0.164 mm was the optimal value, and counter punch force made the largest contribution of 25.89%. In addition, with die roll zone width as the quality objective, the optimal value was 1.274 mm, and V-ring height of the cavity made the largest contribution of 29.45%. Subsequently, this study selected fracture zone depth and die roll zone width as multi-criteria quality objectives and used the robust multi-criteria optimal approach and Pareto-optimal solutions to perform multi-criteria optimization analysis. The results revealed the optimal fracture zone depth and die roll zone width were 0.239 mm and 1.288 mm, respectively. Finally, the experimental results verified that the fracture zone depth was 0.230 mm and die roll zone width was 1.205 mm. The findings met the industry’s fraction zone depth standard (below 12% of blank thickness) and achieved a smaller die roll zone width.

The effects of tool geometry change on shearing edge finish in fine-blanking of different materials

2003 ◽  
Vol 217 (8) ◽  
pp. 1057-1062 ◽  
Author(s):  
Y C Leung ◽  
L C Chan ◽  
C H Cheng ◽  
T C Lee
Keyword(s):  
Tool Geometry ◽  
Nose Radius ◽  
Fine Blanking ◽  
Burr Height ◽  
Service Period ◽  
Edge Surface ◽  
Edge Quality ◽  
Processing Material ◽  
Die Roll ◽  
Blanking Process

An excellent quality of shearing edge implies that a smooth cutting edge without tearing will be observed on the whole edge surface. This is one of the most significant features of the fine-blanking process. To achieve this good blanking edge quality in fine-blanking, quite a large number of factors need to be considered simultaneously during the operation, such as blanking speed, processing material, product shape, lubrication and tool geometry. Thus, the objective of this paper is mainly to study the influence of tool geometry change in fine-blanking for different materials. This is because the nose radius usually seriously deteriorates with increasing service period in mass production, which eventually causes the entire loss of the specific features of the fine-blanking process. Therefore, a tailor-made experimental study was carried out to investigate the relationship between the punch nose radius and the shearing edge quality, such as the shearing edge surface finish, burr height and die-roll height, during fine-blanking for different types of materials. Consequently, findings show that an increase in the punch nose radius produces a higher percentage of fracture of the blanked edge and increases the amount of burr height.

Application of Fine Blanking to the Manufacture of a Sprocket with Stainless Steel Sheet

2004 ◽  
Vol 261-263 ◽  
pp. 1665-1670 ◽  
Author(s):  
Y.H. Seo ◽  
Byoung Kee Kim ◽  
H.D. Son
Keyword(s):  
Stainless Steel ◽  
Unit Cost ◽  
Damage Model ◽  
Hardness Test ◽  
Simple Method ◽  
Fine Blanking ◽  
3 Dimensional ◽  
Deform 2D ◽  
Die Roll ◽  
Blanking Process

Wire cutting(EDM) or blanking is used to made workpieces from sheet metal. Wire EDM provides a relatively simple method for making holes of any desired cross section in material. But EDM requires a lot of working time and the high unit cost of production. In conventional blanking, for the production of precision devices or assemblies, it is always necessary that at least two, but generally more, secondary operations are required per piece part. Using the fine blanking process, a precise finished part with inner and outer forms clearly sheared over the whole material thickness are produced in one single operation. In this study an attempt is made to manufacture a sprocket with fine blanking process. The sprocket is parts for the tape feeder of surface mount system in electronic parts. First, a change of the existing design is made in a sprocket. The materials selected are three kinds of stainless steel, SUS304, SUS316 and SUS430. And the mechanical properties are investigated through the tensile test. After fine blanking, hardness and precision are examined with hardness test and 3-dimensional coordinate measuring for samples. The results of investigations of fine-blanking process with the help of FEM code, DEFORM 2D, are presented. For the simulation, SUS304 and SUS316 are used as materials. The damage model of Cockroft and Latham is used to calculate damage. Die-roll height, die-roll width, burnish zone and fracture zone from the fine blanking simulation are investigated in comparison with them of samples. And the applied force at each part of fine-blanking die is estimated with load-stroke diagram.

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.

scholarly journals Experimental Investigation of Process Forces and Part Quality for Fine Blanking of Stainless Steel with Inductive Heating

2021 ◽  
Author(s):  
Ingo Felix Weiser ◽  
Robby Mannens ◽  
Andreas Feuerhack ◽  
Thomas Bergs
Keyword(s):  
Stainless Steel ◽  
High Strength Steels ◽  
High Strength ◽  
Martensite Phase ◽  
Inductive Heating ◽  
Fine Blanking ◽  
Quality Properties ◽  
Process Forces ◽  
Die Roll ◽  
Blanking Process

Fine blanking is a highly productive process of industrial mass production with which high quality components in particular but not exclusively for the automotive industry are produced. The manufacturing process faces its limits at elevated tensile strengths of the materials to be processed. Consequently, high-strength steels can currently only be fine blanked to a limited extent. This can be overcome by lowering the flow stress of high-strength steels by means of inductive heating. A steel of high importance especially for industries with high hygiene standards such as medical and nutrition production is the stainless steel X5CrNi18-10 (1.4301). As a metastable austenitic steel which can initiate cutting impact on the press through martensitization, fine blanking of stainless steel is a challenge. X5CrNi18-10 is not a high-strength steel per se but becomes difficult to process due to the high hardness of the martensite phase, known as transformation-induced plasticity (TRIP) effect. Thus, in order to combine the possible advantages of the fine blanking process with inductive heating and the important properties of stainless steel, fine blanking of this steel was investigated with inductive heating prior to the fine blanking. The process forces and product quality properties such as die roll were investigated and found to be advantageous in comparison to non-heated fine blanking specimens of the same steel. The process forces and the die roll height decreased due to the heating.

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 A Study Of The Die Roll Height Of SHP-1 And SCP-1 Materials In The Fine Blanking Process

2015 ◽  
Vol 60 (2) ◽  
pp. 1397-1402 ◽  
Author(s):  
C.K. Lee ◽  
Y.C. Kim
Keyword(s):  
Shear Rate ◽  
Steel Sheet ◽  
Ferrite Phase ◽  
Fine Blanking ◽  
Cold Rolled ◽  
Die Roll ◽  
Blanking Process

Abstract The height of the die roll, the distance of the V-ring, and the shear rate were varied with the aim of investigating the effects of the applied changes on the fine blanking line in a cold-rolled and a pickled steel sheet, referred to as SCP-1 and SHP-1, respectively. Both materials consisted primarily of a ferrite phase with small amounts of impurities including F, Mn, and Cr. The distance was found to be a very important factor in controlling the shear of the V-ring in the fine blanking process. When the position of the V-ring was set at distances of 1.5 mm and 2 mm, the die roll height increased with increasing shear speeds from 6.4 m/min to 10 and 16 m/min. Analysis of the influence of the shear rate revealed that low rates resulted in the lowest die roll heights since the flow of material was effectively inhibited.

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