Master of Simulation Techniques Lecture No.

5 Fine Blanking

Prof. Dr.-Ing. F. Klocke

Structure of the lecture Blanking

Sheared surface and force Wear Blanking processes and blanking tools Errors on sheared workpieces

Fine blanking
Comparison to normal blanking Process details and degree of difficulty Tool setup and tool materials Examples of fine blanking parts

Calculation of blanking processes

analytical calculation method FEA of fine blanking processes

Separation processes

Phases in shearing

Influence of die clearance on the formation of cracks and sheared surfaces

Sheared surface in blanking

Quality of sheared surface depending on specific die clearance

Components of cutting force in blanking

Qualitative diagram of cutting force in dependence on the cutting way

Reduction of cutting force by modification of tools

Structure of the lecture Blanking

Sheared surface and force Wear Blanking processes and blanking tools Errors on sheared workpieces

Fine blanking
Comparison to normal blanking Process details and degree of difficulty Tool setup and tool materials Examples of fine blanking parts

Calculation of blanking processes

analytical calculation method FEA of fine blanking processes

Forms of wear on cutting punches

Structure of the lecture Blanking

Sheared surface and force Wear Blanking processes and blanking tools Errors on sheared workpieces

Fine blanking
Comparison to normal blanking Process details and degree of difficulty Tool setup and tool materials Examples of fine blanking parts

Calculation of blanking processes

analytical calculation method FEA of fine blanking processes

Open and closed cut in shearing

Differentiation of blanking and perforating

Sectional image of tool guiding construction

Multi-stage blanking tool

Example for multi-stage punching

Structure of the lecture Blanking

Sheared surface and force Wear Blanking processes and blanking tools Errors on sheared workpieces

Fine blanking
Comparison to normal blanking Process details and degree of difficulty Tool setup and tool materials Examples of fine blanking parts

Calculation of blanking processes

analytical calculation method FEA of fine blanking processes

Geometry errors on blanked parts

Influence of the specific die clearance on the crack depth

Structure of the lecture Blanking

Sheared surface and force Wear Blanking processes and blanking tools Errors on sheared workpieces

Fine blanking
Comparison to normal blanking Process details and degree of difficulty Tool setup and tool materials Examples of fine blanking parts

Calculation of blanking processes

analytical calculation method FEA of fine blanking processes

Comparison blanking - fine blanking

Process sequence of fine blanking

Animation fine blanking

Comparison of sheared surface in blanking and fine blanking

Structure of the lecture Blanking

Sheared surface and force Wear Blanking processes and blanking tools Errors on sheared workpieces

Fine blanking
Comparison to normal blanking Process details and degree of difficulty Tool setup and tool materials Examples of fine blanking parts

Calculation of blanking processes

analytical calculation method FEA of fine blanking processes

Influence of stress state on the ductility

Stress states in the cutting zone in fine blanking

Fine blanked parts

Fine blanked parts

Characteristics of quality of a fine blanked workpiece

Correlations of process variables in fine blanking

Structure of the lecture Blanking

Sheared surface and force Wear Blanking processes and blanking tools Errors on sheared workpieces

Fine blanking
Comparison to normal blanking Process details and degree of difficulty Tool setup and tool materials Examples of fine blanking parts

Calculation of blanking processes

analytical calculation method FEA of fine blanking processes

Definition of degree of difficulty in fine blanking

Fine blanking of a disc

Geometry of vee rings

Forces in fine blanking

Fine blanking of a disc by multi step blanking

Structure of the lecture Blanking

Sheared surface and force Wear Blanking processes and blanking tools Errors on sheared workpieces

Fine blanking
Comparison to normal blanking Process details and degree of difficulty Tool setup and tool materials Examples of fine blanking parts

Calculation of blanking processes

analytical calculation method FEA of fine blanking processes

Fine blanked control disc (one step blanking)

Knife of an electric tin opener

Fine blanking of a clutchdisc

Quality of sheared surface and margin area properties

Whler-diagram for perforated sheet : Comparison fine blanking / machining

Structure of the lecture Blanking

Sheared surface and force Wear Blanking processes and blanking tools Errors on sheared workpieces

Fine blanking
Comparison to normal blanking Process details and degree of difficulty Tool setup and tool materials Examples of fine blanking parts

Calculation of blanking processes

analytical calculation method FEA of fine blanking processes

Calculation of blanking process

Analytical calculation method

Principals and drawbacks

FEA of (fine)blanking processes

Advantage over analytical calculation by means of examples

Calculation of blanking process - cutting force

FS max = s lS k S

maximum cutting force s :sheet thickness lS :length of cutting line kS :cutting resistance

kS = 0,8 Rm

approximate calculation with tensile strength

Calculation of blanking process - cutting energy

WS = FS (x )dx
0

xg

cutting energy x :cutting distance FS :current cutting force

WS = c x g FS max

c :correction factor including variables like material properties, effective cutting distance, size of die clearance and friction

Calculation of fine blanking process - vee ring force

FR = 4 l R hR Rm

approximation value for the vee ring force

lR :length of vee ring hR :overall height of vee ring Rm :material tensile strength

Calculation of fine blanking process - counter punch force

FG = Aq q G

approximation for the counter punch force Aq :cutting piece surface qG :specific counter punch force

qG = 20 qG = 70

N mm2 N mm 2

Value of the specific counter punch force for small sized, thin workpieces.

Value of the specific counter punch force for big, thick workpieces.

Calculation of fine blanking process - cutting force

FS = FSt FG
kS = C1 = FS max FS max = AS lS s kS Rm

cutting force FSt :punch force FG :counter punch force shearing resistance Fsmax :maximum cutting force AS :shearing surface factor of shearing strength kS :shearing resistance Rm :tensile strength calculation according to VDI-standard 3345 lg :total length of cutting lines s :material thickness S :shear strength C1 :factor of shearing strength due to yield stress ratio Rm :material tensile stress advised value is C1= 0,9 (safety)

FS = l g s S = C1 l g s Rm

0,6 < C1 < 0,9

Structure of the lecture Blanking

Sheared surface and force Wear Blanking processes and blanking tools Errors on sheared workpieces

Fine blanking
Comparison to normal blanking Process details and degree of difficulty Tool setup and tool materials Examples of fine blanking parts

Calculation of blanking processes

analytical calculation method FEA of fine blanking processes

Simulation fine blanking

Simulation of fine blanking offers the opportunity to include: flow stress data friction properties thermomechanical coupling More exact input data can be enclosed:

instead of

FS = C1 lg s Rm
Rm = const .

This leads to the following results: force over punch travel stress field strain rate field draw-ins prediction of fracture

Simulation fine blanking: Example

material flow

detail

Simulation fine blanking: Example

damage

Simulation fine blanking: Example

strain-rate

Simulation fine blanking: Example

strain

Simulation fine blanking: material flow as a function of friction

Simulation fine blanking: Example

maximum principle stress in blanking punch and workpiece forces in the tool: blanking die blankholder blanking punch counterpunch

Simulation fine blanking: Example

stresses in the tool

Simulation blanking: Example

workpiece fracture - deleting elements

detail

Simulation fine blanking: Example

3D-simulation - draw-ins

Simulation fine blanking: Example

3D-simulation - strain

Questions What does the sheared surface look like in blanking ? Why is this surface not completely smooth ? Please explain the punch force over punch travel for blanking ! Why are blanking tools made of hardened and tempered material ? Why are sheet metal parts of high quantity made preferably through blanking and not through CNC-wire Electro-erosion ? What is the maximum stroke frequency of a blanking machine ? Why is there an increased fraction of smooth surface in fine blanking in comparison to normal blanking ? What is the reason behind the difficulty classes in fine blanking ? Why can a protruding part be not arbitrarily thin ? Why can a radius not be arbitrarily small ? Can hardened and annealed materials be used as workpiece material in fine blanking ? What is the maximum plastic strain in fine blanking ?