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Improvement of product quality using negative clearance grooved punch

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Abstract

Center cracks frequently occur during extrusion cutting. These cracks are often caused by uneven material flow velocities, which may also increase the material’s hardness and cause surface fractures and unevenness. In this study, simulations and experiments were performed to determine whether a novel grooved punch can stabilize the material flow velocity of a billet during extrusion cutting. The relationship between the punch and die outlet geometry was also investigated. If the punch dimensions are smaller than those of the die outlet, the product shrinks and fractures. Larger punches can prevent these defects but increase the material flow velocity, causing sinking at the center. Finite element analysis and experiments conducted with grooved punches revealed that both shallow and deep grooves can improve the control of material flow and delay acceleration. Punches with greater volume both increase and stabilize the material’s acceleration. The dimensions of the grooved punch must be similar to those of the die outlet to ensure optimal material flow.

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Acknowledgements

The authors would like to express our gratitude to the Ministry of Science and Technology of Taiwan for their financial assistance extended to a part of this study, which makes the experimental work possible. This research under Contract No. MOST 109-2221-E-019-003-MY2. They are also grateful to SFTC for help in running the DEFORM-3D software.

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Authors and Affiliations

  1. Research Center of Material Processing and Measurement, Department of Marine Engineering, National Taiwan Ocean University, No.2 Beining Road, Zhongzheng District, Keelung City, 20224, Taiwan, Republic of China

    Kuo-Ming Huang

  2. Department of Marine Engineering, National Taiwan Ocean University, No.2 Beining Road, Zhongzheng District, Keelung City, 20224, Taiwan, Republic of China

    Ming-Huang Hsu, Joseph Ramanuel & Chuan-Hsaing Chang

  3. Metal Industries Research & Development Center, 1001 Kaonan Highway, Nanzi Dist, Kaohsiung City 811, Taiwan, Republic of China

    Jiang-Ming Wey

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  1. Kuo-Ming Huang
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Contributions

All authors certify that have participated sufficiently in the work to take public responsibility for content. First concept and draft of the manuscript was written or revision by Kuo-Ming Huang. Ming-Huang Hsu and Joseph Ramanuel on material preparation, data collection and analysis were performed the analysis with constructive discussions. Chuan-Hsaing Chang and Jiang-Ming Wey were performed the experiment design and testing. Furthermore, each author certifies that this technology or similar manufacturing technology has not been and will not be submitted to or published in any other publication before its appearance in the “The International Journal of Advanced Manufacturing Technology.”

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Correspondence to Kuo-Ming Huang.

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Huang, KM., Hsu, MH., Ramanuel, J. et al. Improvement of product quality using negative clearance grooved punch. Int J Adv Manuf Technol 125, 479–492 (2023). https://doi.org/10.1007/s00170-022-10383-0

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  • DOI: https://doi.org/10.1007/s00170-022-10383-0

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