The effects of punch angle in noise and force formation for sheet metal blanking process

The paper is concerned with the effect of punch angle (0°, 4°, 8°, 16°), sheet thickness (0.8, 2 mm), and punch speed (25, 37.5 mm / min) on the force formation and noise in the blanking of DP600 dual-phase steel sheet. The blanking experiments were carried out in a modular blanking die. The blanking force and noise variables were obtained simultaneously during the blanking using a load cell and noise measuring device, respectively. It was determined that the blanking force significantly decreased with an increasing punch angle, while noise formation decreased. The increase in the punch speed slightly increased the amount of noise while it did not affect the blanking force significantly.

Impact of orbiting electrode motion on the accuracy of electrical discharge machining

The present study is designed to study processes occurring during the electrical discharge machining (EDM) of tool steels, the influence of orbiting electrode motion on its accuracy, as well as to justify the application of individual orbiting trajectories and implement these data into production. To that end, a trajectory program was written in machine codes for a Mitsubishi EA-28 die-sinking electrical discharge machine using the CIMCO EDIT software package. Also, a prototype punch and ejector of the blanking die were produced and measured. The standard modes of Mitsubishi EA-28 were used to carry out machining in Blasospark GT 250 dielectric fluid to a roughness of Ra 0.6 in 9 passes. The experiments revealed the influence of electrode geometry on the machining of sharp corners, i.e., the formation of unwanted radii on the workpiece. However, this phenomenon is not observed when the corners are drilled with small diameter holes (0.4–0.6 mm). Depending on the machining process along the inner or outer trajectory, inverse electrode motion is also observed. The production part (punch of the blanking die) was machined using a new orbit adjusted to the geometry of the product. The part was found to be consistent with the requirements and the engineering drawing, thus allowing the assembled die to enter the main production. The results of the performed tests, as well as the study of domestic and foreign experience, were used to develop recommendations on the use of individual orbits in the EDM of tool steels, hard alloys, and other hard-to-machine conductive materials. The method of orbiting motion along a particular trajectory was implemented at Cheboksary Electrical Apparatus Plant (Cheboksary).

Wear Mechanism and Ability for Recovery of Tool Steel on Blanking Die Process

Tool steel grade JIS; SKD-11 is a well-known raw material for making a high wear resistance of blanking tool in stamping industry. One problem in the blanking process is the high cost of raw material for making punch and die. Therefore, in this study, behavior of wear phenomenon and ability of recycle on the punch of blanking die process were investigated. In the first section, phenomenon and mechanism wear of blanking punch were observed. We found that mechanism of wear on blanking punch was adhesion wear, since high amount of chromium content in the punch has compatibility of elements. The second section, recovery punch was designed by annealing, resize and quenching process by using the new punch from the first section. From the recovery punch results, it was found that the wear resistance of recovery punch decreased slightly but it was strong enough to continue in blanking process. However, the recycle process of tool steel depends on a quality and amount of the product.

Research and Development of a Knowledge-Based System for Blanking Die

This paper presents the research work involved in the development of knowledge based system (KBS) for blanking die. Automotive covering parts stamping production as one of the important chain of automobile manufacturing, especially the design of blanking die played a vital role. And the success of blanking die design often rely on the experience and knowledge of experts. And because of the knowledge of "privacy", new mold production designer is difficult to be familiar with the design processes and structure parameters in a short period. Such a phenomenon extended the production cycle, and increased manufacturing costs. This topic from the perspective based on knowledge, by means of integration, in view of the blanking die design of similar offers ways and means to solve the problem.

Computer Aided Design of the Die-Set for Sheet Metal Punching and Blanking Dies

Die-Set is one of the Punching/Blanking die components. It includes lower and upper shoes, guide posts and guide bushes. The High demand of Die-Set in industry resulted in the supply of specified die set from many manufacturing companies. The standard components in the market cover only the small and medium die sizes. In many cases, the designers need to build their own die-sets especially in case of progressive die design and non-tradition die sizes. In this paper, a CAD system for building a Die-Set is discussed. This system is built using Visual Basic (VB) interfacing with AutoCAD. The system covers all Die-Sets sizes (small, medium). The proposed CAD system is prepared to work as a standalone or as a subroutine for a blanking die design CAD system. It saves time in Die-Set design operation from hours to minutes. This module is a part of a series of studies to automate the design of sheet metal working tools.

Assembly Key of Precise Blanking Punching Compound Die

Taking the example of precise gasket blanking die, the author introduces that the key of compound die assembly is adjusting the gap between moulds which directly influences the quality of products and the dies lifetime. When assembling, one must assure the uniformity of the gap between the terrace and sunken die.

The Optimization to the Die of Concave-Convex Blanking Material

To increase the service life of the die in blanking stainless steel plate, this paper tries to optimize the blanking die. By adopting reasonable lifting and pushing structure in the die to realize up-put the concave and down-lie the convex which adds the sharpening repair times of concave-convex die. The study finds that the die is easy to operate and maintain and has the character of repeating sharpening repair after one-time heat treatment, which can greatly prolong the dies service life and is suitable to bulk blank stainless steel plate.