Experimental Study of Shearing Dimensional Parameters in the Sheet Metal Blanking Process of StW24 Steel with a Thickness of 12 mm

الموضوعات :

Farshid Ahmadi ¹ (Department of Mechanical Engineering, University of Kashan, Kashan 8731753153, Iran)
Amir Abdollahi ² (Department of Mechanical Engineering, University of Kashan, Kashan 8731753153, Iran)
Saeid Zamani ³ (Department of Mechanical Engineering, Jami Institute of Higher Education, Fuladshahr, Isfahan, Iran)

تاريخ الإرسال : 06 الأربعاء , شوال, 1444 تاريخ التأكيد : 02 الثلاثاء , ذو الحجة, 1444 تاريخ الإصدار : 11 الإثنين , شوال, 1444

الکلمات المفتاحية: Fracture angle, Shear zone, clearance, The sheet metal blanking, rollover zone, burr and StW24,

ملخص المقالة :

Blanking is a sheet metal cutting process,which itself is a prerequisite for many other forming processes. Punch and matrix shape and material, punch force and speed, lubricant, corner radius, and punch-matrix clearance are important variables in blanking. Clearance is critical in this process, depending on the material and sheet thickness, and is usually a percentage of the sheet thickness. Too much clearance causes the sheet to press and pull into the clearance area and Low clearance causes misaligned fracture lines and secondary cutting. Producing blanking with high thicknesses is always one of the challenges of the sheet metal blanking process. This study aims to create 57.5 mm diameter StW24 steel blanks with 12 mm thickness and a 38% penetration value. A blanking die was designed and built with different punches based on clearance values of 9, 15, and 21% to match the target drawing. Results show that increasing clearance from 9 to 15% leads to an 11% thicker rollover zone, 5% thicker fracture zone, and 33% thinner shear zone. Increasing clearance from 15 to 21% reduces the thickness of rollover, fracture, and shear zones by 24, 3, and 56% respectively. Increasing clearance from 9 to 21% also leads to a 51% increase in fracture angle and a 34% increase in burr size. Clearance of 15% of sheet thickness is best for producing blank as per the target drawing.

المصادر:

[1] Verlinden, B., Driver, J., Samajdar, I. and Doherty, R.D. 2007. Thermo-mechanical processing of metallic materials. Elsevier,

[2] Eary, D.F. and Reed, E.A. 1974. Techniques of pressworking sheet metal. An engineering approach to die design.  Second Edition. Prentice-Hall, London and Sydney and Englewood Cliffs.

[3] CustomPartNet. 2023. Https://www.Custompartnet.Com/.

[4] Committee, A.H. 1970. Metals handbook (forming) ed. American Society for Metals, Ohio.

[5] Fan, W. and Li, J. 2009. An investigation on the damage of aisi-1045 and aisi-1025 steels in fine-blanking with negative clearance.  Materials Science and Engineering: A. 499(1-2): 248-251.

[6] Kut, S. 2010. The application of the formability utilization indicator for finite element modeling the ductile fracture during the material blanking process.  Materials & Design. 31(7): 3244-3252.

[7] Marouani, H., Ismail, A.B., Hug, E. and Rachik, M. 2009. Numerical investigations on sheet metal blanking with high speed deformation.  Materials & Design. 30(9): 3566-3571.

[8] Mackensen, A., Golle, M., Golle, R. and Hoffmann, H. 2010. Experimental investigation of the cutting force reduction during the blanking operation of ahss sheet materials.  CIRP annals. 59(1): 283-286.

[9] Falconnet, E., Makich, H., Chambert, J., Monteil, G. and Picart, P. 2012. Numerical and experimental analyses of punch wear in the blanking of copper alloy thin sheet.  Wear. 296(1-2): 598-606.

[10] Subramonian, S., Altan, T., Ciocirlan, B. and Campbell, C. 2013. Optimum selection of variable punch-die clearance to improve tool life in blanking non-symmetric shapes.  International Journal of Machine Tools and Manufacture. 75: 63-71.

[11] Murakawa, M., Suzuki, M., Shionome, T., Komuro, F., Harai, A., Matsumoto, A. and Koga, N. 2014. Precision piercing and blanking of ultrahigh-strength steel sheets.  Procedia Engineering. 81: 1114-1120.

[12] Komori, K. 2014. Simulation of stationary crack during blanking using node separation method.  Procedia Engineering. 81: 1102-1107.

[13] Slavič, J., Bolka, Š., Bratuš, V. and Boltežar, M. 2014. A novel laboratory blanking apparatus for the experimental identification of blanking parameters.  Journal of Materials Processing Technology. 214(2): 507-513.

[14] Demmel, P., Hoffmann, H., Golle, R., Intra, C. and Volk, W. 2015. Interaction of heat generation and material behaviour in sheet metal blanking.  CIRP Annals. 64(1): 249-252.

[15] Hou, H., Li, H., He, L. and Tang, B. 2017. Analysis of phase transformation and blanking accuracy of b1500hs steel during hot blanking.  Procedia engineering. 207: 1528-1533.

[16] Maiti, S., Ambekar, A., Singh, U., Date, P. and Narasimhan, K. 2000. Assessment of influence of some process parameters on sheet metal blanking.  Journal of Materials Processing Technology. 102(1-3): 249-256.

[17] Fang, G., Zeng, P. and Lou, L. 2002. Finite element simulation of the effect of clearance on the forming quality in the blanking process.  Journal of Materials Processing Technology. 122(2-3): 249-254.

[18] Husson, C., Correia, J., Daridon, L. and Ahzi, S. 2008. Finite elements simulations of thin copper sheets blanking: Study of blanking parameters on sheared edge quality.  Journal of materials processing technology. 199(1-3): 74-83.

[19] Ismail Ghadiri Zahrani, M.Z., Hamid Abiyar. 2010. Investigation and experimental estimation of crack growth angle, compression length and depth of compression in symmetrical blnking process. Proc. 10th ICME 2010 National Manufacturing Engineering Conference.  Babol, Iran.

[20] Anoushirvan Farshidian Far, A.R.A., Saeed Abbasiyoun. 2006. Optimum clearance prediction in the blanking process by minimizing the height of the burr. Proc. The fourteenth annual international conference on mechanical engineering.  Isfahan, Iran.

[21] Tambe, M.L.T. and Sadattulla, M.M.U. 2023. Mathematical model development & clearance optimization in sheet metal blanking process for copper. 3(5): 460-465.

[22] Çavuşoğlu, O. 2022. An investigation of punch radius and clearance effects on the sheet metal blanking process.  International Journal of Automotive Science And Technology. 6(4): 309-316.

[23] Gharehchahi, H., Kazemzadeh-Parsi, M.J., Afsari, A. and Mohammadi, M. 2020. Numerical study of effective parameters in the deep drawing process of a cylindrical cup and comparison with experimental results.  Journal of Modern Processes in Manufacturing and Production. 9(2): 31-42.

[24] Gharehchahi, H., Kazemzadeh-Parsi, M.J., Afsari, A. and Mohammadi, M. 2020. A new geometry modification algorithm for blank shape optimization in the deep drawing process.  Journal of Modern Processes in Manufacturing and Production. 9(4): 15-25.

[25] Rahmani, F. and Hashemi, S.J. 2021. Numerical and experimental investigation of thickness distribution in hydromechanical deep drawing process of square parts.  Journal of Modern Processes in Manufacturing and Production. 10(2): 5-12.

[26] Boljanovic, V. and Paquin, J.R. 2005. Die design fundamentals.  New York: Industrial Press.