Deep rolling of fine blanking punch edges
- 476 Downloads
Fine blanking is an economical process to manufacture components with a high sheared edge quality. Fine blanking of high-strength steels leads to an increase of the wear of fine blanking punches and deteriorates the economical efficiency of this process. In preliminary work lateral surfaces of cylindrical punches made of different hardened steels industrially used for tool manufacturing were deep rolled. Under proper process parameters a reduction of surface roughness, a hardness increase as well as an induction of compressive residual stresses in the surface layer were achieved. Therefore, deep rolling has a potential to improve the wear resistance of fine blanking punches. In order to improve the quality of the sheared edge of a workpiece, fine blanking punches must have a round fillet on the cutting edge. Filleting through plastic deformation can improve the wear resistance of this most loaded region of the fine blanking punch. In order to perform the filleting of the cutting edge through plastic deformation and to induce strain hardening and compressive residual stresses into the edge region a novel profiled deep rolling tool is developed in this work. Furthermore, the technical feasibility of the edge deep rolling with regard to the processing of fine blanking punches is assessed for the first time. The approach is based on a numerical modeling and experimental investigation of edge deep rolling.
KeywordsMechanical surface treatment Deep rolling Fine blanking Finite element method
The authors would like to thank the Federal Ministry for Economic Affairs and Energy within the Central Innovation Program SME Initiative (ZIM) for partly funding this research work. Further, we express our gratitude to the following industrial partners for their support: Karl Scharrenbroich GmbH & Co.KG, Ecoroll AG Werkzeugtechnik.
- 6.Schulze V, Schwing JK (2006) Modern mechanical surface treatment. States, stability, effects. Wiley-VCH, WeinheimGoogle Scholar
- 7.Altenberger I (2005) Deep rolling-the past, the present and the future. In: Schulze V, Niku-Lari A (eds) Proceedings of 9th International Conference on Shot Peening ICSP-9, Paris, FranceGoogle Scholar
- 8.Niku-Lari A (1987) Advances in surface treatments. Pergamon Press, OxfordGoogle Scholar
- 12.Klocke F, Shirobokov A, Mattfeld P, Feuerhack A (2014) Festwalzen von Feinschneidstempeln (in german) 10:660–665. wt-onlineGoogle Scholar
- 13.Hoffmann H (2012) Handbuch Umformen (in german) Hanser, MnchenGoogle Scholar
- 14.Picas I, Hernndez R, Casellas D, Valls I (2010) Strategies to increase the tool performance in punching operations of UHSS. In: Proceedings of IDDRG 2010 Graz, Austria, pp 325–334Google Scholar
- 15.Röttger K (2003) Walzen hartgedrehter Oberflächen (in german). RWTH Aachen University, DissertationGoogle Scholar
- 16.Mader S (2006) Festwalzen von Fan- und Verdichterschaufeln (in german). RWTH Aachen University, DissertationGoogle Scholar
- 17.Manouchehrifar A, Alasvand K (2009) Finite element simulation of deep rolling and evaluate the influence of parameters on residual stress. In: Tsuomu K (ed) Recent Researches in Applied Mechanics. WSEAS Press, Athens, pp 121–127Google Scholar
- 24.Achmus C, Jung U, Kaiser B, Wohlfahrt H (1997) FEM-simulation des festwalzens von kurbelwellen (in german). Konstruktion 10:31–34Google Scholar
- 25.Systemes Dassault (2014) Abaqus Analysis User’s Guide: Prescribed Conditions, Constraints & InteraltionsGoogle Scholar