Prediction of Shear Length in Blanking Process by Numerical Analysis

Abstract:

Blanking process has high productivity compared with other cutting processes. Because of this feature, the blanking process is used for the manufacture of automobile parts, electronic parts and so on. However, the blanking process is the process that leads to fracture. When the cutting surface are used as the functional surface, such as gears or cams, the precision of cutting surface is important and it can be improved by applying appropriate process conditions. The appropriate process conditions have been determined by repeating many experiments and this process is very inefficient. Owing to this background, the determination of the optimal process condition by numerical method such as the finite element method (FEM) is expected. In the previous studies, blanking process analyses of round blanking process which were modeled as 2D axisymmetric problem have been carried out and the cutting surface that coincided well with the experimental result was obtained. However, the blanking shape was not taken into consideration and they were not considering whether it can be applied to complicated shape expected to be applied in the future. In this study, blanking process analysis of quadrilateral blanking process was modeled as 2D plane strain problem and the applicability of various ductile fracture criteria was examined by comparing numerical results with experimental results based on shear length. As a result, there was little difference in the applicability of Cockcroft and Latham, Ayada, Brozzo ductile fracture criterion to the prediction of shear length under the current conditions.

• Periodical: Materials Science Forum (Volume 920)
• Pages: 181-186
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.920.181
• Online since: April 2018
• Authors: Shusuke Sato*, Masaki Omiya
• Keywords: Blanking Process, Ductile Fracture Criterion, Finite Element Method (FEM), Plane Strain, Shear Length

References

[1] Toru Tanaka, Seiya Hagihara, Yuichi Tadano, Takuma Inada, Takanobu Mori, Kenji Fuchiwaki, Ductile Fracture Criteria for Cutting surfaces of Punching Process by Finite Element Method, Journal of JSTP, vol.52, No.609(2011), pp.1104-1108.

DOI: 10.9773/sosei.52.1104

[2] Sutasn Thipprakmas, Masahiko Jin, Kanaizuka Tomokazu, Yamamoto Katsuhiro, Masao Murakawa, Prediction of Fineblanked surface characteristics using the finite element method(FEM), Journal of Materials Processing Technology, Vol.198 (2008).

DOI: 10.1016/j.jmatprotec.2007.07.027

[3] Kwak, T.S., Kim, Y.J., Bae, W.B., Finite element analysis on the effect of die clearance on shear planes in fine blanking, Journal of Materials Processing Technology, Vol.130(2002),pp.462-468.

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

[4] Kai Wang, Tomasz Wierzbicki, Experimental and numerical study on the plane-strain blanking process on an AHSS sheet, International Journal of Fracture, Vol. 194, No.1(2015), pp.19-36.

DOI: 10.1007/s10704-015-0034-1

[5] M.G. Cockcroft and D.J. Latham, Ductility and the Workability of Metals, Journal of the Institute of Metals, Vol.96 (1968), pp.33-39.

[6] Ayada,M., Higashino,T., Mori,K., Central bursting in extrusion of inhomogeneous materials, Proceeding of 1st ICTP, Advanced Technology of Plasticity, Vol.1 (1984), pp.553-558.

[7] P. Brozzo, B. Deluca, R. Redina, A new method for the prediction of formability limits in metal sheets, Proc. of the seventh biannual conf. of IDDRG(1972).