Abstract
Investigating the shear zone temperature is one of the major challenges in the study of high-speed blanking in thick sheet metals. Several studies have shown that a clear temperature change occurs even at low speed and that this significantly influences the blanked edge quality and die life; however, the thermal effects of high-speed blanking of thick sheet metals have received comparably little attention. This study proposes a methodology to predict the temperature distribution in the blanking process using a coupled thermo-mechanical finite element method for thin phosphorous bronze. The finite element model of blanking was developed to characterize the quality of the blanked edge for different punch speeds. The effect of material softening due to the heat generated during plastic work was considered in the blanking simulations. To verify the validity of the proposed model, several simulations were performed and the results, such as the blanking force and proportion of sheared area, were compared with those obtained from experimental studies. It was found that the thermal effect in thin phosphorous bronze at high punch speeds does not significantly affect the product quality. Therefore, a higher productivity can be attained while maintaining a high quality of the finished product using high-speed blanking.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Huang ZY (2007) Research the key technology in the high speed precision progressive stamping for the IT products. Ph. D. thesis, South China University of Technology, China
Balakrishnan M, Issac JC (2014) Design of the multi-stage progressive tool for blanking a sheet metal component. Int J Precis Eng Manuf 15(5):875–881
Nishad R, Totre A, Bodke S, Chauhan A (2013) An overview of the methodologies used in the optimization processes in sheet metal blanking. Int J Mech Eng Robotic Res 2(2):307–314
Marouani H, Ben Ismail A, Hug E, Rachik M (2009) Numerical investigations on sheet metal blanking with high speed deformation. Mater Des 30(9):3566–3571
Faura F, Garcia A, Estrems M (1998) Finite element analysis of optimum clearance in the blanking process. J Mater Process Technol 80–81:121–125. doi:10.1016/S0924-0136(98)00181-2
Rafsanjani A, Abbasion S, Farshidianfar A, Irani N (2009) Investigation of the viscous and thermal effects on ductile fracture in sheet metal blanking process. Int J Adv Manuf Technol 45(5):459–469
Falconnet E, Makich H, Chambert J, Monteil G, Picart P (2012) Numerical and experimental analyses of punch wear in the blanking of copper alloy thin sheet. Wear 296:598–606
Mucha J (2010) An experimental analysis of effects of various material tool’s wear on burr during generator sheets blanking. Int J Adv Manuf Technol 50:495–507
Lo SP, Chan DY, Lin YY (2007) Quality prediction model of the sheet blanking process for thin phosphorous bronze. J Mater Process Technol 194:126–133
Soares JA, Gipiela ML, Lajarin SF, Marcondes PVP (2013) Study of the punch-die clearance influence on the sheared edge quality of thick sheets. Int J Adv Manuf Technol 65:451–457
Goijaerts AM, Govaert LE, Baaijens FPT (2002) Experimental and numerical investigation on the influence of process speed on the blanking process. J Manuf Sci Eng 124:416–419
Pen XG, Lu X, Balendra R (2004) FE simulation of the blanking of electrically heated engineering materials. J Mater Process Technol 145:224–232
Miri K, Maeno T, Fuzisaka S (2012) Punching of ultra-high strength steel sheets using local resistance heating of shearing zone. J Mater Process Technol 212:534–540
Sartkulvanich P, Kroenauer B, Golle R, Konieczny A, Altan T (2010) Finite element analysis of the effect of blanked edge quality upon stretch flanging of AHSS. CIRP Ann-Manuf Technol 59(1):279–282
Lestriez P, Saanouni K, Mariage JF, Cherouat A (2004) Numerical prediction of ductile damage in metal forming processes including thermal effects. Int J Damage Mech 13:59–80
Brokken D (1999) Numerical modeling of ductile fracture in blanking. Ph. D. thesis, Eindhoven University of Technology, the Netherlands
Lin ZC, Chang DY (2009) A band-type network model for the time-series problem used for IC leadframe dam-bar shearing process. Int J Adv Manuf Technol 40:1252–1266
Goyal S, Karthik V, Kasiviswanathan KV, Valsan M, Bhanu K, Rao S, Raj B (2010) Finite element analysis of shear punch testing and experimental validation. Mater Des 31:2546–2552
Subramonian S (2013) Improvement of punch and die life and part quality in blanking of miniature parts. Ph. D. thesis, The Ohio State University, USA
Subramonian S, Altan T, Campbell C, Ciocirlan B (2013) Determination of forces in high speed blanking using FEM and experiments. J Mater Process Technol 213(12):2184–2190
Cockcroft MG, Latham DJ (1968) Ductility and the workability of metals. J Inst Met 96:33–39
Fang G, Zeng P, Lou LL (2002) Finite element simulation of the effect of clearance on the forming quality in the blanking process. J Mater Process Technol 122:249–254
Pen YH, Huang ZY, Qiu HY (2007) The obtaining of the fracture criteria of QSn6.5-0.1. Mech Elec Eng Technol 36(3):55–56
Slavic J, Bolka S, Bratus V, Boltezar M (2014) A novel laboratory blanking apparatus for the experimental identification of blanking parameters. J Mater Process Technol 214:507–13
Gaudilliere C, Ranc N, Larue A, Maillard A (2013) High speed blanking: an experimental method to measure induced cutting forces. Exp Mech 53(7):1117–26
Gaudilliere C, Ranc N, Larue A, Lorong P (2010) Investigations in high speed blanking: cutting forces and microscopic observations. EPJ Web Conf, EDP Sci 6:19003
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Hu, DC., Chen, MH., Ouyang, JD. et al. Finite element analysis of the thermal effect in high-speed blanking of thick sheet metal. Int J Adv Manuf Technol 80, 1481–1487 (2015). https://doi.org/10.1007/s00170-015-6954-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-6954-0