Skip to main content
SpringerLink
Log in

Further observations and review of numerical simulations of sheet metal punching

  • Original Article
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In this report, a numerical study into the punching process is presented. During the simulations, the Gurson/Tvergaard damage model is applied in order to model void nucleation and growth. Particular attention is given in this paper to some of the inherent assumptions of both the damage mechanics model and its implementation in the finite element code, including the simulation of the process of void nucleation and growth and the role of hydrostatic pressure in the clearance zone. In spite of the fundamental nature of the assumptions, the numerical simulations compare favourably against experimental results. In order to aid further developments in damage modelling and its application in finite element simulations of punching, a number of suggestions for further investigations are presented.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

Abbreviations

c :

Clearance (D d-D p)/2h 0

C :

Work hardening factor [MPa]

d :

Displacement of the punch [mm]

D p :

Diameter of round punch [mm]

D d :

Diameter of die [mm]

e :

Engineering strain

E :

Young’s modulus [GPa]

F d :

Force on the die edge in the axial direction [N]

F p :

Instantaneous punching force in the axial direction [N]

F p,max :

Maximum punching force [N]

H 0 :

Initial blank thickness [mm]

n :

Work hardening exponent

q 1,2,3 :

Tvergaard constants

S N :

Standard deviation for void nucleation (Gurson/Tvergaard)

\(\overline{{\text{ $ \varepsilon $ }}}\) :

Von Mises equivalent strain

εN :

Mean strain value for void nucleation (Gurson/Tvergaard)

\(\overline{{\text{ $ \sigma $ }}}\) :

Von Mises equivalent stress [MPa]

σ0.2 :

Proof stress [MPa]

σ1,2,3 :

Principal stresses [MPa]

σB :

Ultimate tensile strength [MPa]

σm :

Hydrostatic stress [MPa]

σy :

Yield stress [MPa]

τ:

Shear stress [MPa]

υ:

Void volume fraction (Gurson/Tvergaard)

υc :

Void volume fraction (Gurson/Tvergaard), coalescence

υ*:

Bilinear function of the void volume fraction (Gurson/Tvergaard)

υN :

Volume fraction of void nucleating particles (Gurson/Tvergaard)

References

  1. Klingenberg W, Singh UP (2003) Finite element simulation of the punching process using in-process characterisation of mild steel. J Mater Process Technol 134(3):296–302

    Article  Google Scholar 

  2. Klingenberg W (2000) Numerical modelling of the punching process using in-process characterisation of steel. PhD dissertation, University of Ulster, Newtownabbey, UK

  3. Chen ZH, Tang CY, Lee TC, Chan LC (2002) Numerical simulation of fine-punching process using a mixed finite element method. Int J Mech Sci 44(7):1309–1333

    Article  MATH  Google Scholar 

  4. Goijaerts AM, Govaert LE, Baaijens FPT (2001) Evaluation of ductile fracture models for different metals in punching. J Mater Process Technol 110:312–323

    Article  Google Scholar 

  5. Goijaerts AM, Govaert LE, Baaijens FPT (2000) Prediction of ductile fracture in metal blanking. J Manuf Sci Eng-T ASME 122:476–483

    Article  Google Scholar 

  6. Klocke F, Sweeney K, Raedt HW (2001) Improved tool design for fine punching through the application of numerical modeling techniques. J Mater Process Technol 115:70–75

    Article  Google Scholar 

  7. Hambli R (2001) Punching tool wear modelling using the finite element method. Int J Mach Tools Manuf 41(12):1815–1829

    Article  Google Scholar 

  8. Taupin E, Breitling J, Wu W-T, Altan T (1996) Material fracture and burr formation in punching results of FEM simulations and comparison with experiments. J Mater Process Technol 59:68–78

    Article  Google Scholar 

  9. Lange K (1985) Handbook of metal forming. McGraw-Hill, New York, Chap. 24

    Google Scholar 

  10. Gurson AL (1977) Continuum theory of ductile rupture by void nucleation and growth: part 1—yield criteria and flow rules for porous ductile media. J Manuf Sci Eng-T ASME 39:2–15

    Google Scholar 

  11. Tvergaard V, Needleman A (1984) Analysis of the cup-cone fracture in a round tensile bar. Acta Metall 32(1):157–169

    Article  Google Scholar 

  12. Needleman A, Tvergaard V (1991) A numerical study of void distribution effects on dynamic, ductile crack growth. Eng Fract Mech 38(2/3):157–173

    Article  Google Scholar 

  13. Tvergaard V (1987) Ductile shear fracture at the surface of a bent specimen. Mech Mater 6:53–69

    Article  Google Scholar 

  14. Tvergaard V (1981) Influence of voids on shear band instabilities under plane strain conditions. Int J Fract 17(4):389–407

    Article  Google Scholar 

  15. Lemaitre J (1985) A continuous damage mechanics model for ductile fracture. J Manuf Sci Eng-T ASME 107:83–89

    Google Scholar 

  16. McClintock FA (1968) A criterion for ductile fracture by the growth of holes. J Appl Mech 363–371

  17. Cockcoft MG, Latham DJ (1968) Ductility and workability of metals. J Inst Met 96:33–39

    Google Scholar 

  18. Rice JR, Tracey DM (1969) On the ductile enlargement of voids in triaxial stress fields. J Mech Phys Sol 17:210–217

    Article  Google Scholar 

  19. Singh UP, Wilson R, Hinduja S (1985) Computer aided study of a single column hydraulic press. In: Proceedings of the 25th international MTDR conference, Birmingham, vol 25, pp 389–395

  20. Singh UP (1977) Numerical analysis of the distortional behaviour of a hydraulic press. Annals CIRP 16(1):119

    Google Scholar 

  21. Singh UP, Kals HJJ, Streppel AH (1990) Computer aided design study of a die-set for punching/punching. In: Proceedings of the 28th international MTDR conference, Manchester, vol 28, pp 379–386.

  22. Singh UP, Klingenberg W, Urquhart W (1994) Effect of tool geometry on punching performance. J Manuf Sci Eng-T ASME 116:508–513

    Google Scholar 

  23. Dieter GE, Bacon D (1988) Mechanical metallurgy, SI metric edn. McGraw-Hill, New York, pp 262–268

    Google Scholar 

  24. Atkins AG (1980) On cropping and related processes. Int J Mech Sci 22:215–231

    Article  Google Scholar 

  25. Zhou Q, Wierzbicki T (1996) A tension model of punching and tearing of ductile metal plates. Int J Mech Sci 38(3):303–324

    Article  Google Scholar 

  26. Ghosh A, Raghu Ram V, Popat PB (1985) A new approach to the mechanics of the punching operation: theoretical model and experimental verification. J Mech Work Technol 11:215–228

    Article  Google Scholar 

Download references

Acknowledgements

The authors wish to sincerely thank Daehwa Metal Ltd. (UK) for supporting this research programme, of which also [1] was a result.

Author information

Authors and Affiliations

  1. University of Groningen, Groningen, The Netherlands

    W. Klingenberg

  2. University of Ulster, Newtownabbey, Northern Ireland, UK

    U. P. Singh

Authors
  1. W. Klingenberg
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. U. P. Singh
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to U. P. Singh.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Klingenberg, W., Singh, U.P. Further observations and review of numerical simulations of sheet metal punching. Int J Adv Manuf Technol 30, 638–644 (2006). https://doi.org/10.1007/s00170-005-0120-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-005-0120-z

Keywords

Search

Navigation