Three Dimensional Finite Element Simulation of Sheet Metal Blanking Process

Abstract:

The shearing process such as the blanking of sheet metals has been used often to prepare workpieces for subsequent forming operations. The use of FEM simulation is increasing for investigation and optimizing the blanking process. In the current literature a blanking FEM simulations for the limited capability and large computational cost of the three dimensional (3D) analysis has been largely limited to two dimensional (2D) plane axis-symmetry problems. However, a significant progress in modelling which takes into account the influence of real material (e.g. microstructure of the material), physical and technological conditions can be obtained by using 3D numerical analysis methods in this area. The objective of this paper is to present 3D finite element analysis of the ductile fracture, strain distribution and stress in blanking process with the assumption geometrical and physical nonlinearities. The physical, mathematical and computer model of the process are elaborated. Dynamic effects, mechanical coupling, constitutive damage law and contact friction are taken into account. The application in ANSYS/LS-DYNA program is elaborated. The effect of the main process parameter a blanking clearance on the deformation of 1018 steel and quality of the blanks sheared edge is analyzed. The results of computer simulations can be used to forecasting quality of the final parts optimization.

• Periodical: Applied Mechanics and Materials (Volume 474)
• Pages: 430-435
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.474.430
• Online since: January 2014
• Authors: Łukasz Bohdal, Leon Kukielka, Krzysztof Kukielka, Agnieszka Kułakowska, Leszek Malag, Radoslaw Patyk
• Keywords: 3D Sheet Metal Blanking Process, Finite Element Method (FEM), Numerical Analysis, Numerical Modeling

References

[1] P. Demmel, T. Kopp, R. Golle, W. Volk, H. Hoffmann, Experimental investigation on the temperature distribution in the shearing zone during sheet metal blanking, Steel Research International, Special Edition on Metal Forming, (2012) 291-294.

DOI: 10.4028/scientific5/amr.445.207

[2] T.S. Kwak, Y.J. Kim, W.B. Bae, Finite element analysis on the effect of die clearance on shear planes in fine blanking, J. of Mat. Proc. Tech. 462-8 (2002) 130-131.

DOI: 10.1016/s0924-0136(02)00767-7

[3] R. Hambli, Finite element model fracture prediction during sheet-metal blanking process, Eng. Fract. Mech. 68 (2001) 365-378.

DOI: 10.1016/s0013-7944(00)00106-5

[4] M. Murakawa, Advanced Technology of Plasticity, vol. II, Tokyo (1984) 805.

[5] B. Bösch, F. Büzer, K. Hayashi, Advanced Technology of Plasticity, vol. II, Tokyo (1984) 815.

[6] A. Ghosh, V. Reghuram, P.B. Popet, A new approach to the mechanics of the blanking operation, J. Mech. Work. Technol. (1985) 215.

[7] H. Hayashi, M. Mori, K. Yoshida, Shape Failure in Flanging of Sheet Metal, IDDRG, Amsterdam, (1986).

[8] M. Samuel, FEM simulations and experimental analysis of parameters of influence in the blanking process, J. of Mat. Proc. Tech. 84 (1998) 97-106.

DOI: 10.1016/s0924-0136(98)00083-1

[9] A. Kulakowska, L. Kukielka, Numerical analysis and experimental researches of burnishing rolling process with taking into account deviations in the surface asperities outline after previous treatment, Steel Research International 2 (2008) 42-48.

DOI: 10.1002/pamm.200810733

[10] A. Kulakowska, Problems of surface preparation under burnishing rolling in aspect of product quality, Steel Research International 81 (9) (2010) 218-221.

[11] R. Patyk, L. Kukielka, Optimization of geometrical parameters of regular triangular asperities of surface put to smooth burnishing, Steel Research International 2 (2008) 642-647.

[12] R. Patyk, Theoretical and experimental basis of regular asperities about triangular outline embossing technology, Steel Research International 81 (9) (2010) 190-193.

[13] Ł. Bohdal, P. Walczak, Eco-modeling of metal sheet cutting with disc shears, Annual Set The Environment Protection 15 (2013) 863-872.

[14] L. Kukielka, K. Kukielka, Numerical analysis of the physical phenomena in the working zone in the rolling process of the round thread, in: J.T.M. de Hosson, C.A. Brebbia, S-I Nishida (Eds. ), Computer Methods and Experimental Measurements for Surface Effects and Contact Mechanics VIII, WITPRESS, Southampton-Boston (2007).

DOI: 10.2495/secm070121

[15] L. Kukielka, K. Geleta, K. Kukielka, Modelling and Analysis of Nonlinear Physical Phenomena in the Burnishing Rolling Operation with Electrical Current, Steel Research International Special Edition on Metal Forming (2012) 1379-1382.

[16] L. Kukielka, K. Kukielka, Numerical analysis of the process of trapezoidal thread rolling, in: C.A. Brebbia (Eds. ), High Performance Structures and Materials III, WITPRESS, Southampton-Boston (2006) pp.663-672.

DOI: 10.2495/hpsm06065