materials

Article
Elucidation of Shearing Mechanism of Finish-type FB
and Extrusion-type FB for Thin Foil of JIS SUS304 by
Numerical and EBSD Analyses
Yohei Suzuki 1, *, Tomomi Shiratori 1 , Ming Yang 2 and Masao Murakawa 3
1 Komatsuseiki kosakusho. Co., Ltd., 942-2 Shiga, Suwa, Nagano 392-0012, Japan
2 Tokyo Metropolitan University, 6-6, Asahigaoka, Hino, Tokyo 191-0065, Japan
3 Nippon Institute of Technology, 4-1 Gakuenndai, Miyashiro, Minamisaitama, Saitama 345-8501, Japan
* Correspondence: y-suzuki@komatsuseiki.co.jp; Tel.: +81-266-52-6100




Received: 3 June 2019; Accepted: 1 July 2019; Published: 3 July 2019


Abstract: A numerical analysis using FE (finite element) analysis was performed to clarify the
shearing mechanism in the process of extrusion-type fine blanking (FB) for a thin foil of JIS SUS304
in this study. Extrusion-type FB, in which a negative clearance between the punch and the die has
been developed and investigated experimentally to improve the quality of the sheared surface in
the blanking of thin foils. The resultant sheared surface for extrusion-type FB indicated an almost
completely sheared surface, and the fracture portion on the sheared surface was much smaller
than that in conventional FB, the so-called finish-type FB. The material flow and fracture criteria
in extrusion-type FB were analyzed in comparison with those in finish-type FB. The differences in
material flow and so-called critical fracture value were verified for the two processes. The principal
stress near the shearing surface has mostly compressive components in extrusion-type FB due to
its negative clearance, and the critical fracture value was also less than that in finish-type FB, in
which the principal stress near the shearing surface has mostly tensile components. Furthermore,
SEM observation with EBSD (electron back-scatter diffraction) analysis of the shearing surface was
performed to verify the phenomena. Reductions in deformation-induced crystal orientation rotation
and martensite transformation in extrusion-type FB were confirmed in comparison with those in
finish-type FB from the analysis results.

Keywords: fine blanking; metallic microgear; finite element analysis; electron backscatter diffraction;
critical fracture value

1. Introduction
Recently, the notable miniaturization of electronic devices and medical instruments has been
observed. Accordingly, the miniaturization of their components and their high-precision capability is
also required [1]. The fabrication of microparts with complex profiles using stamping press machines
is attractive owing to its high productivity. Blanking is one of the typical stamping processes used to
rapidly cut parts with complex profiles from sheet metal, and fine blanking (FB) [2] can be used to make
a part with a fine shearing surface. However, problems due to the miniaturization of parts arise in
microblanking. As parts become smaller, the sheet becomes thinner. In general, the clearance between
the punch and the die is expressed as the ratio to the thickness of the sheet, so the absolute value of the
clearance also decreases as the sheet thickness decreases [3]. According to findings on the FB process
at the macro scale, the clearance is assumed to less than 1% of the thickness t [4]. Since a sheet of
0.1 mm thickness or less is usually used in microblanking, the clearance becomes 1 µm or less and, as a
consequence, the manufacturing accuracy of the die and the positioning accuracy of the punch and
die are approaching their limits [5]. Furthermore, when the thickness of the work material decreases,

Materials 2019, 12, 2143; doi:10.3390/ma12132143 www.mdpi.com/journal/materials

Materials 2019, 12, x FOR PEER REVIEW 2 of 10
Materials 2019, 12, 2143 2 of 10
clearance becomes 1 μm or less and, as a consequence, the manufacturing accuracy of the die and the
positioning accuracy of the punch and die are approaching their limits [5]. Furthermore, when the
fracture is likely to occur owing to the effects of the surface roughness of the material and the crystal
thickness of the work material decreases, fracture is likely to occur owing to the effects of the surface
grain size [6–9], which affects the product accuracy. To solve these problems, the authors previously
roughness of the material and the crystal grain size [6–9], which affects the product accuracy. To solve
developed a novel FB process and demonstrated its advantages by an experimental comparison with
these problems, the authors previously developed a novel FB process and demonstrated its
the conventional FB process using a general-purpose precision stamping press machine [10]. The
advantages by an experimental comparison with the conventional FB process using a general-
conventional FB process is finish-type FB with an extremely narrow positive tool clearance and a
purpose precision stamping press machine [10]. The conventional FB process is finish-type FB with
counterpunch. The newly developed process is extrusion-type FB with a negative tool clearance and
an extremely narrow positive tool clearance and a counterpunch. The newly developed process is
a counterpunch pressure pad. By comparing the results, the developed process was found to be
extrusion-type FB with a negative tool clearance and a counterpunch pressure pad. By comparing the
superior from the most important viewpoint of suppressing the fracture of the surface. However, the
results, the developed process was found to be superior from the most important viewpoint of
material flow and fracture mechanism have not yet been clarified, and furthermore, the most important
suppressing the fracture of the surface. However, the material flow and fracture mechanism have not
parameters in the process are unknown.
yet been clarified, and furthermore, the most important parameters in the process are unknown.
In this study, an FE analysis is performed to clarify the material flow and fracture mechanism in
In this study, an FE analysis is performed to clarify the material flow and fracture mechanism in
extrusion-type FB in comparison with finish-type FB, particularly from the viewpoint of suppressing
extrusion-type FB in comparison with finish-type FB, particularly from the viewpoint of suppressing
fracture or cracking on the shearing surface during the FB process. Furthermore, the mechanism of
fracture or cracking on the shearing surface during the FB process. Furthermore, the mechanism of
fracture suppression was verified by SEM observation with EBSD (electron back-scatter diffraction)
fracture suppression was verified by SEM observation with EBSD (electron back-scatter diffraction)
analysis, which enables the observation of the material deformation state using the information
analysis, which enables the observation of the material deformation state using the information
obtained by the orientation analysis of the crystallinity of the shearing surface of samples.
obtained by the orientation analysis of the crystallinity of the shearing surface of samples.
2. FEM Simulation Model and Conditions
2. FEM Simulation Model and Conditions
Figure 1 shows SEM images of microgears fabricated by finish-type FB and extrusion-type FB [10].
Figure
As described1 shows SEM images
previously, of microgears
the shearing fabricated
surface of by finish-type
the microgear FBby
processed and extrusion-type
extrusion-type FBFB
is
[10]. As described previously, the shearing surface of the microgear processed by extrusion-type
smoothly sheared without fracture in comparison with that processed by finish-type FB. FB
is smoothly sheared without fracture in comparison with that processed by finish-type FB.

Direction of blanking 1.0 mm Direction of blanking 1.0 mm

(a) finish-type FB (b) extrusion-type FB

Figure 1. SEM
Figure images
1. SEM of of
images thethe
microgear
microgear[10]:
[10]: (a)
(a) finish-type FB;(b)(b)
finish-type FB; extrusion-type
extrusion-type FB. FB.

To elucidate
To elucidate thethe mechanism
mechanism of of fracture
fracture suppression,
suppression, we we developed
developed an an analysis
analysis model
model for for both
both
FB methods
FB methods for for use
use inin FE
FE simulation,
simulation, andand the
the model
model andand its
its conditions
conditions are are shown
shown in in Figure
Figure 22 and
and
Table 1,
Table 1,respectively.
respectively.The The microgear
microgear waswas assumed
assumed to axisymmetric
to be be axisymmetric about about the gear
the gear centerline,
centerline, and
aand a two-dimensional
two-dimensional model model
waswas applied
applied in in
thisthis simulation
simulation totoreduce
reducethe the calculation
calculation time.
time. The
The
commercially available FEM
commercially FEM (Finite
(Finiteelement
elementmethod)
method)code codeDEFORM2D
DEFORM2D (Ver.11.1)
(Ver.11.1)waswasutilized for for
utilized the
simulation.
the The The
simulation. punch punch Fp was
forceforce Fpprocessed as a constant
was processed displacement
as a constant Fp was
type, i.e.,type,
displacement calculated
i.e., Fp was
as the reaction
calculated as theforce Fm offorce
reaction the workpiece. The workpiece
Fm of the workpiece. used was aused
The workpiece JIS SUS304
was a JISsheet with asheet
SUS304 thickness
with
at of 0.178 mm,
thickness t ofand
0.178a microgear
mm, and aworkpiece
microgearhaving
workpiecean outer
havingdiameter
an outer ϕDw of 3.5
of diameter of mm
φDwwas used
of 3.5 mm to
correspond
was used to to the experiment
correspond to the at conditionsatofconditions
experiment the press ofin the press
previousin thereport [10]. In
previous our [10].
report present
In
FE analysis,
our present FE theanalysis,
outer peripheral
the outeredge of the workpiece
peripheral edge of thewas assumed
workpiece to assumed
was be constrained, as shown in
to be constrained,
Figure
as shown 2, since a coil2,material
in Figure having
since a coil sufficient
material having width relative
sufficient to the
width size oftothe
relative themicrogear
size of thewas used in
microgear
the experiment, and there was no material flow in the width direction of the material.
was used in the experiment, and there was no material flow in the width direction of the material. A A die diameter
ϕDd1
die of 1.752φD
diameter mm d1 (tool clearance
of 1.752 Cl ofclearance
mm (tool 2 µm) was Clused
of 2 for
μm)finish-type
was usedFB, forand a die diameter
finish-type FB, and ϕD of
ad2die
1.732 mm φD
diameter (clearance Cl ofmm
d2 of 1.732 −8 µm) was used
(clearance Clfor
of extrusion-type
−8 μm) was used FB. The
forpunch diameter ϕDp
extrusion-type FB. ofThe1.748 mm
punch
and the counterpunch
diameter φDp of 1.748 mm diameter ϕDc
and the of 1.720 mmdiameter
counterpunch were commonφDc ofto1.720
bothmm processes. The punch,
were common die
to both
and blank The
processes. holder/stripper
punch, die were assumed
and blank to be rigid bodies,
holder/stripper were and the workpiece
assumed to be rigid was assumed
bodies, andtothe
be
elastoplastic.
workpiece was Approximately
assumed to be 15,000 four-nodeApproximately
elastoplastic. rectangular elements
15,000 were generated
four-node on the workpiece.
rectangular elements
Since generated
were the deformation
on theisworkpiece.
concentrated in an
Since theextremely
deformationnarrow range in the deformation
is concentrated in an extremely areanarrow
around
range in the deformation area around the cutting edge of the tool, there is significant distortion in the
Materials 2019, 12, 2143 3 of 10
Materials 2019, 12, x FOR PEER REVIEW 3 of 10

elements
the [11]. The
cutting edge simulation
of the tool, thereresult in a previous
is significant FB study,
distortion in thewhich revealed
elements the relationship
[11]. The between
simulation result in
the meshFB
a previous size andwhich
study, the clearance
revealed Cl,
the was referredbetween
relationship to for the
thedetermination of the
mesh size and the mesh size
clearance [12].
Cl, was
Specifically,
referred to for the mesh size in the
determination ofanalysis
the mesh was
sizeset to about
[12]. 1 μm, which
Specifically, is smaller
the mesh thananalysis
size in the the clearance
was
setCl.
toIn such1aµm,
about casewhich
whereisthe deformation
smaller than theofclearance
the elements
Cl. Inwas
suchapparently large,
a case where theadeformation
remeshing function
of the
was adopted
elements to rebuild large,
was apparently the meshes.
a remeshing function was adopted to rebuild the meshes.

Figure2.2.FEM
Figure FEMsimulation model.
simulation model.
Table 1. FEM simulation conditions.

Simulation Model Type Axisymmetric Model

Object type Workpiece: elasto-plastic (ϕDw :3.5 mm)
Punch /Die: rigid (ϕDp :1.748 mm, ϕDd1 :1.752 mm, ϕDd2 :1.732 mm)
Blank holder /Stripper: rigid
Counterpunch: rigid (ϕDc :1.720 mm)
Clearance (Cl) Finish-type FB: 2 µm
Extrusion-type FB: −8 µm
Blank holder force (FB ) 1000 N (50% of maximum blanking force)
Counterpunch force (FC ) 400 N (20% of maximum blanking force)
Blanking force (FP ) Non-constant value
Radii of tool cutting edges Rp = 0.00 mm, Rd = 0.01 mm
Figure 3. Flow stress-plastic strain
SUS304 curve.
t = 0.178 mm
Work material (Workpiece) Young’s modulus: 193 GPa
Poisson’s
Table 1. FEM simulation ratio: 0.3
conditions.
Fracture criterion equation Cockcroft and Latham
Simulation Model Type Axisymmetric Model
Friction coefficient (µ) 0.08
Object type Workpiece: elasto-plastic (φDw : 3.5 mm)
Punch /Die: rigid (φDp : 1.748 mm, φDd1 : 1.752 mm, φDd2 : 1.732 mm)
The material constants were derived from the data Blank holderfrom
available /Stripper: rigidexperimental tensile
an actual
Counterpunch:
test giving the flow stress-plastic strain curve shown in Figure 3.rigid (φDc : 1.720
Furthermore, tomm)
verify and observe
the fracture process(Cl)
Clearance in both FB methods, we used the damage value
Finish-type FB:C2(critical
μm fracture value [13])
obtained from the ductile fracture criterion [14] of Cockcroft and Latham
Extrusion-type defined
FB: −8 μm as the value of the
integral corresponding
Blank holder forceto(Fthe
B) evolution of the 1000
maximum
N (50%principal stress blanking
of maximum as follows:force)
Counterpunch force (FC) 400
Z εN (20% of maximum blanking force)
Blanking force (FP) σmax Non-constant value
C = dε (1)
Radii of tool cutting edges 0 σRp = 0.00 mm, Rd = 0.01 mm
SUS304 t = 0.178 mm
where C: critical fracture value, σmax : maximum principal stress, σ: effective stress, and ε: effective strain.
Work material (Workpiece) Young’s modulus: 193 GPa
Poisson’s ratio: 0.3
Fracture criterion equation Cockcroft and Latham
Materials 2019, 12, 2143 4 of 10
Figure 2. FEM simulation model.

Materials 2019, 12, x FOR PEER REVIEW 4 of 10

Friction coefficient (μ) 0.08

The material constants were derived from the data available from an actual experimental tensile
test giving the flow stress-plastic strain curve shown in Figure 3. Furthermore, to verify and observe
the fracture process in both FB methods, we used the damage value C (critical fracture value [13])
obtained from the ductile fracture criterion [14] of Cockcroft and Latham defined as the value of the
integral corresponding to the evolution of the maximum principal stress as follows:

C 𝑑𝜀̅ (1)
Figure3.3.Flow
Figure Flow stress-plastic
stress-plastic strain
straincurve.
curve.
where C: critical fracture value, 𝜎 : maximum principal stress, 𝜎: effective stress, and 𝜀̅: effective
strain. Table 1. FEM simulation conditions.
The friction coefficient was assumed to be 0.08, referring to the value recommended by DEFORM2D
The
for cemented friction
carbide
Simulation coefficient
dies.Type
Model was
Although assumed to bea 0.08,
there was concern referring to Model
that the
Axisymmetric the valuemay
friction recommended by
change significantly
DEFORM2D
during the blanking for cemented
Object process,
type carbide dies. Although there
Workpiece:
as a result of examining was a concern
elasto-plastic
them that the
(φDw : 3.5
in the report friction
of mm) may change
Sasada et al. [15]. It was
significantly during the blanking process, as arigid
result ofp examining themd1 : in themm,
report of d2 :Sasada et al.
reported that the FEM analysis agrees well with the blanking result even if the φD
Punch /Die: (φD : 1.748 mm, φD 1.752 friction 1.732 mm)
coefficient was
[15]. It was reported that the FEM analysis agrees well Blank with the blanking
holder result even if the friction
/Stripper: rigid
constant. Accordingly, the coefficient of friction was set constant in this study. The temperature was
coefficient was constant. Accordingly, the coefficient of frictionrigid
Counterpunch: was(φD
setc :constant
1.720 mm) in this study. The
set temperature
to be constant wasinset
this
Clearance analysis.
to(Cl)
be constant Although temperature
in this analysis. Although changes occur
temperature
Finish-type FB: 2 μm in the tool
changes andinmaterial
occur the tool during
blanking, the ratio of heat flow to the material
and material during blanking, the ratio of heat flow to could be considered
Extrusion-type
the material FB:negligibly
could −8 μm small owing
be considered negligibly to the small
volume ratio of
Blank the material
holder force (Fto) the die at the microscale.
1000 N (50% of maximum
small owing to the small volume ratio of the material to the die at the microscale.
B blanking force)
Counterpunch force (FC) 400 N (20% of maximum blanking force)
3. FEM Simulation
3. FEM Blanking Results
Simulation force (FP) and Discussion
Results Discussion Non-constant value
Radii of tool cutting edges Rp = 0.00 mm, Rd = 0.01 mm
Since
Since fractureoccurred
fracture occurred at
at a punch
punchstroke
strokeofof
about
about80% of the
80% of sheet thickness t according to our
SUS304 t =the sheet
0.178 mm thickness t according to our
previous
previousWork experimental
experimental results [10] for finish-type FB,
results [10] for finish-type FB, the damage
the damage values (critical
values fracture
(critical values)values)
fracture at a at a
material (Workpiece) Young’s modulus: 193 GPa
punch stroke of 80% were investigated for both
punch stroke of 80% were investigated for both processes. processes. Figure 4
Figureratio:
Poisson’s shows
4 shows a comparison
0.3 a comparison of the of thedamage
damage valuecriterion
Fracture between a) finish-type FB and b) extrusion-type
equation Cockcroft FB in the case of the punch
value between a) finish-type FB and b) extrusion-type FB in and
the Latham
case of the punch penetration. In
penetration. In the case of finish-type FB, the result shows that damage accumulated in the region
the case of finish-type FB, the result shows that damage accumulated in the region connecting the
connecting the punch shoulder and die. In the case of extrusion-type FB, the damage value was also
punch
highshoulder andshoulder
in the punch die. In the
andcase of extrusion-type
punch FB, theindamage
side, but it was lower valueincluding
other regions was alsothe
high in the punch
shearing
shoulder
zone, which means that some allowance remains to prevent fracture. This was in agreement with the means
and punch side, but it was lower in other regions including the shearing zone, which
thatexperimental
some allowance
resultsremains
obtainedtowith
prevent fracture.
an actual Thispress
stamping was machine
in agreement with
in which the experimental
extrusion type FB did results
obtained with
not cause anbreakage
any actual stamping pressofmachine
or separation in which
the workpiece, extrusion
even type FB
at 80% punch did not cause
penetration anythe
through breakage
sheet thickness t [10].
or separation of the workpiece, even at 80% punch penetration through the sheet thickness t [10].

Punch Punch
Blank holder Blank holder Damage value

Blanking Blanking
direction direction
Scrap side Scrap side

Product side Product side

Die Die

Counterpunch Counterpunch

a) finish-type FB b) extrusion-type FB

Figure 4. Comparison
Figure of damage
4. Comparison value
of damage defined
value as theasintegration
defined value value
the integration corresponding to the evolution
corresponding to
of the
the maximum principal
evolution of stress σmax
the maximum for 80%t
principal stress 𝜎 penetration
punch between
for 80%t punch finish-type
penetration fine blanking
between
(FB) and extrusion-type FB: (a) finish-type FB; (b) extrusion-type FB.
Materials 2019, 12, x FOR PEER REVIEW 5 of 10
Materials 2019, 12, x FOR PEER REVIEW 5 of 10
Materials 2019, 12,fine
finish-type 2143blanking (FB) and extrusion-type FB: (a) finish-type FB; (b) extrusion-type 5 of 10
finish-type fine blanking (FB) and extrusion-type FB: (a) finish-type FB; (b) extrusion-type
FB.
FB.
The The
vonvon Mises
Mises stress
stress andand maximum
maximum principal
principal stressstress distributions
distributions for both forFB
both FB methods
methods are shownare shown
The
Figures von 5 Mises
and 6,stress and
respectively,maximum
for the principal
same stress
condition distributions
of punch for both
penetration FB
in Figures 5 and 6, respectively, for the same condition of punch penetration of 80% as in Figure 4. It 4. It
in methods
of 80% are
as in shown
Figure
in
was
was Figures
found
found 5 and
that,
that, 6,although
respectively,
although thethevon for
von the
Mises
Mises same condition
stresses
stresses forfor
both ofFB
both punch
FB penetration
methods
methods showed
showed ofsimilar
80% asdistributions,
similarindistributions,
Figure 4. It the
was
the found that,
maximum
maximum although
principal
principal stressthedistributions
stress von Mises stresses
distributions were for both FB different.
weresignificantly
significantly methods
different.showed
ItItcan
canbe similar
be observeddistributions,
observed that,
that,ininthe case
the
of maximum
finish-type principal
FB, in the stress
area distributions
between the were
scrap significantly
and the different.
product (being It can
the case of finish-type FB, in the area between the scrap and the product (being blanked out), a tensile be
blanked observed
out), a that, in stress
tensile
the case of
distribution
stress finish-type
distribution appears FB, in the
to prevail,
appears area between
while
to prevail, in the
while the
incasescrap and the
of extrusion
the case product
type type
of extrusion (being
FB, a FB, blanked
compressive out),
a compressive a tensile
stressstress
distribution
stress distribution
distribution
prevails. These prevails. appears
These
results to prevail,
areresults while in
are consistent
consistent the case
with the
with the results of extrusion
results
for the type
for the
damage FB,
damage
value a
showncompressive
value shown
in Figure stress
4, in
in which
distribution
Figure 4, in prevails.
which These
higher results
maximum are consistent
principal with
stresses the results
corresponded for the
to damage
higher value
damage shown
values, in
higher maximum principal stresses corresponded to higher damage values, consistent with previous
Figure 4,with
consistent in which
previous higher maximum
knowledge that principal
the stressesstress
compression corresponded
distribution to can
higher
reducedamage values,
knowledge that the compression stress distribution can reduce the damage value andthe damage
suppress fracture
consistent
value with
and suppress previous
fracture knowledge
in if
blanking that the compression stress distribution can reduce the damage
in blanking processes even the vonprocesses evenisifsimilar
Mises stress the von[16].
Mises stress is similar [16].
value and suppress fracture in blanking processes even if the von Mises stress is similar [16].
Punch Punch Blank holder von Mises stress
Blank holder
Punch Punch Blank holder von Mises stress
(MPa)
Blank holder
Blanking (MPa)
Blanking
Blanking Blanking
direction direction
direction direction
Scrap side Scrap side
Scrap side Scrap side

Product side Product side

Die Die
Product side Product side
Die Die

Counterpunch Counterpunch
Counterpunch Counterpunch
a) finish-type FB b) extrusion-type FB
a) finish-type FB b) extrusion-type FB
Figure 5. Comparison of von Mises stress for 80%t punch penetration between the finish-
Figure
Figure
type 5.5. Comparison
FB and Comparison of von
of
extrusion-type von Mises
FBMises
in stress
stress
Figure for
4:for
(a) 80%t
80%t punch
punch
finish-type FB;penetration
penetration between
between the finish-FB and
the FB.
(b) extrusion-type finish-type
type FB and extrusion-type
extrusion-type FB(a)
FB in Figure 4: infinish-type
Figure 4: (a)FB;finish-type FB; (b) extrusion-type
(b) extrusion-type FB. FB.

Blank holder Punch Blank holder

Punch Maximum principal
Blank holder Punch Blank holder
Punch Maximum principal
stress (MPa)
Blanking Blanking stress (MPa)
Blanking Blanking
direction direction
direction direction
Scrap side Scrap side
Scrap side Scrap side

Product side Product side

Product side Product side Die
Die Die
Die

Counterpunch Counterpunch
Counterpunch Counterpunch
a) finish-type FB b) extrusion-type FB
a) finish-type FB b) extrusion-type FB
Figure 6. Comparison of maximum principal stress for 80%t punch penetration between the finish-type
FB and extrusion-type FB in Figure 4: (a) finish-type FB; (b) extrusion-type FB.

From the various reports thus far, it is known that the stress distribution within a material is
related to the material flow in the processing. For example, Huang et al. have shown the effect of
 Materials 2019, 12, x FOR PEER REVIEW 6 of 10

Figure 6. Comparison of maximum principal stress for 80%t punch penetration between
the finish-type FB and extrusion-type FB in Figure 4: (a) finish-type FB; (b) extrusion-type
FB.
Materials 2019, 12, 2143 6 of 10
From the various reports thus far, it is known that the stress distribution within a material is
related to the material flow in the processing. For example, Huang et al. have shown the effect of the
the tool
tool clearance (eitherpositive
clearance (either positiveorornegative)
negative)ononthe thediedieroll
roll during
during blanking
blanking [17],
[17], andand Thipprakmas
Thipprakmas et
et al.al.have clarified
have clarified the mechanism of fracture during FB, in which an extremely
mechanism of fracture during FB, in which an extremely small but positive small but positive
tool
toolclearance
clearancewas wasused
used[18].
[18].However,
However,they theyhavehavenot notyet
yetclarified
clarified
thethe fracture
fracture mechanism,
mechanism, in which
in which a
a positive
positive clearance
clearanceand anda anegative
negativeclearance
clearancemightmightcause
cause different
different fracture
fracture behaviors.
behaviors. The Thematerial
material
flows
flows in both
in both FB processes
FB processes were
were also
also compared
compared atatthe
thesame
samepunch
punchpenetration
penetration of 80% 80% sheet
sheetthickness
thickness
andand Figure
Figure 7 shows
7 shows thethe resultant
resultant material
material flowsininthe
flows theshearing
shearingzone.
zone. In the
the case
case ofof finish-type
finish-typeFB, FB,
the workpiece
the workpiece located
located immediately
immediately under
under thethepunch
punchflowsflowsalmost
almostperpendicularly
perpendicularly to to that
thatin
inthe
thediedie
interior
interior portion,
portion, inducing
inducing material
material flowflow on scrap
on the the scrap
sideside
that that
was was parallel
parallel to interior
to the the interior material
material flow.
flow. Accordingly, we concluded that this material flow behavior generates
Accordingly, we concluded that this material flow behavior generates a tensile stress field between a tensile stress field
between
the scrap the
side ofscrap side of the(which
the workpiece workpiece (whichdown
is pressed is pressed
by thedown
blankby the blank
holder) and holder) and the
the blanked-out
blanked-out
workpiece, workpiece,
resulting resulting in ahigh
in a consequently consequently
cumulative high cumulative
damage value, damage
ultimatelyvalue, ultimately
leading to the
leading to the breakage of the workpiece. In the case of extrusion type FB, a change in the direction
breakage of the workpiece. In the case of extrusion type FB, a change in the direction of the workpiece
of the workpiece flow is observed near the die corner B. In particular, immediately adjacent to point
flow is observed near the die corner B. In particular, immediately adjacent to point B, owing to the
B, owing to the material flow towards the die portion B, the workpiece behaves as if it were self-
material flow towards the die portion B, the workpiece behaves as if it were self-crushed. As a result,
crushed. As a result, we consider that a compressive stress field is generated where fracture is
we consider that a compressive stress field is generated where fracture is suppressed.
suppressed.

Blanking direction Blanking direction

Product Product
A A

Velocity (mm/sec)

Scrap side
B Scrap side
Die Die

a) finish-type FB b) extrusion-type FB

Figure 7. Comparison
Figure 7. Comparison of material flow
of material for for
flow 80%t punch
80%t punchpenetration between
penetration finish-type
between FB and
finish-type FB
extrusion-type FB, in an enlarged view: (a) finish-type FB; (b) extrusion-type FB.
and extrusion-type FB, in an enlarged view: (a) finish-type FB; (b) extrusion-type FB.
4. Discussion Based on EBSD Analysis
4. Discussion Based on EBSD Analysis
The shearing surfaces were observed by SEM with EBSD (electron back-scatter diffraction) to clarify
The shearing surfaces were observed by SEM with EBSD (electron back-scatter diffraction) to
the shearing mechanism for both FB methods. EBSD analysis is an effective methodology for evaluating
clarify the shearing mechanism for both FB methods. EBSD analysis is an effective methodology for
the deformation state of grains in a workpiece. In particular, the KAM (kernel average misorientation) is a
evaluating the deformation state of grains in a workpiece. In particular, the KAM (kernel average
value that indirectlyisrepresents
misorientation) the
a value that degree of
indirectly plastic deformation
represents the degree ofvia the amount
plastic of crystal
deformation orientation
via the amount
and can correspond to the equivalent plastic strain in plastic working [19]. Furthermore, it has been
used to clarify the fracture generation mechanism during microshear processing [20]. Since it is known
that JIS SUS304 transforms from a ductile austenite phase to a brittle martensitic phase depending on
the processing strain, information on the phase transformation will be also useful for understanding the
fracture mechanism.
 Materials 2019, 12, x FOR PEER REVIEW 7 of 10
Materials 2019, 12, x FOR PEER REVIEW 7 of 10
of crystal orientation and can correspond to the equivalent plastic strain in plastic working [19].
ofFurthermore,
crystal orientation it has and beencan used correspond
to clarify tothe thefracture
equivalent plastic mechanism
generation strain in plastic during workingmicroshear[19].
Furthermore,
processing [20]. it has
Sincebeen used tothat
it is known clarify the fracture
JIS SUS304 transforms generation mechanism
from a ductile austenite during phase microshear
to a brittle
Materials 2019,[20].
processing 12, 2143
Since it is known that JIS SUS304 transforms from a ductile austenite phase 7 of 10
to a brittle
martensitic phase depending on the processing strain, information on the phase transformation will
martensitic phase depending on the
be also useful for understanding the fracture mechanism. processing strain, information on the phase transformation will
be also For useful
For sample
sample for preparation
understanding
preparation for forthe
EBSDfracture
EBSD analysis,mechanism.
analysis, first of
first of all,
all, the
the cross
crosssection
section of ofworkpieces
workpieces of ofthethe
For
microgear sample
microgear half-blanked preparation
half-blanked by the punch for EBSD
punch that analysis,
that penetrated
penetratedfirst ofabout all, the
about 60%
60%cross
ofofthesection
thesheet
sheet of workpieces
thickness
thickness forfor ofboth
both theFB
microgear
FBmethods
methods half-blanked
waswas fabricated.
fabricated.by the
Next, punch
it was
Next, that
it cut
wastocutpenetrated
thetoarea about
the shown
area shown 60% of
in Figure the sheet
8, and8,
in Figure thickness
the andsurface for both
was mirror-
the surface FB
was
methods
finished was
mirror-finished fabricated.
by mechanicalby mechanical Next,
polishing it polishing
wasand cution toand
the area
milling. ion EBSD shownanalysis
milling. in EBSD
Figure was8, performed
and the
analysis was surface
at anwas
performed mirror-
acceleration
at an
finished
voltage by
acceleration of 20 mechanical
kV andofa20
voltage polishing
kV andand
measurement ion milling.
interval
a measurement of 0.15 EBSD μm.
interval analysis
of 0.15was
Figure 9µm.
showsperformed
the analysis
Figure at an results
9 shows accelerationin the
the analysis
voltage of
form ofinKAM
results 20 kV
the form and
mapsof a measurement
forKAMthe finish
mapsand interval
forextrusion-type of
the finish andFB 0.15 μm. Figure
methods. Figure
extrusion-type 9 shows
FB 10 the analysis
shows the
methods. results
analysis
Figure in the
results
10 shows
form
in the
the of KAM
form of
analysis maps
phase
results for the
inmaps. finish
the form It was and extrusion-type
foundmaps.
of phase that the It phase FB
was found methods.
transformation Figure
that the phase 10 shows the
fromtransformation analysis
the austenite phase results
from (red the
in the form of phase maps. It was found that the phase transformation
austenite phase (red area) to the martensitic phase (green area) occurs in the areas with high strain inIt
area) to the martensitic phase (green area) occurs in the areas with from
high the
strain austenite
in the KAM phasemaps.(red
area)
was
the KAMto the
found maps.martensitic
that It areas
waswith phase
found a high(green
that area)
strain
areas occurs
of five
with a high in
degrees thered
strain areas fivewith
of areas andhigh
degrees strain
different
red areas inandthedifferent
crystal KAM maps.
orientations crystal It
are
was found
distributed are
orientations that areas
in distributedwith a
the area connecting high strain
in the area the of five degrees
punch the
connecting edge red
punch areas
and edge and
the die different
and corner. crystal
Moreover,
the die corner. orientations
Moreover,the phase are
the
distributed
transformations
phase in
transformations the area
occurred connecting
in areas
occurred the
with high
in areas punch
with strain edge
high strain in bothand the
in methods die
both methods corner.
consistent Moreover,
with with
consistent the
the results phase
of FE
the results
transformations
ofanalysis.
FE analysis. However, occurred
However, inthe
the areas areaswith
areas with
high
with high strain
strain
high and
strain in phase
both
and methods consistent
transformation
phase transformation were with the concentrated
results of
concentrated
were in FEthe
analysis.
inshearing However,
the shearingzone in thethe
zone case areas
in the of case with
finish-type highFB,
of finish-type
strain
while andwhile
FB,they
phase
shifted transformation
theyto the scrap
shifted to the
were
side concentrated
(left
scrap side) in the
for extrusion-
side (left side) for
shearing
type FB.zone
extrusion-type
inFB.
In these theIn case
areas, of finish-type
thesecompression
areas, compression
FB, whilestress
stress isthey shifted and
dominant
is dominant
to thedoes
scrapnot
and does
side (left
contribute
not
side) for
contribute
extrusion-as
to fracture,
to fracture,
type FB.
described In these
ininthe areas, compression stress is dominant and does not contribute to fracture, as
as described thelast
lastsection.
section.By Byassuming
assumingthat thatcracks
cracks occur occur along the vertical shearing shearing line line(white
(white
described in
linesininFigures the
Figures9 9and last
and section.
10), By assuming
a difference that
in strain cracks occur
concentration along the
on white vertical
the white shearing
line (length line (white
of about 80
lines 10), a difference in strain concentration on the line (length of about 80 µm)
lines in
μm)becan Figures
be for 9
seenthe and
fortwo 10), a
themethods. difference
two methods. in strain
Figure concentration
11 shows the KAM on the white
values line
along (length of about 80
can seen Figure 11 shows the KAM values along the thelinelinefrom from point
point a toa
μm) can be
to point seen for the two methods. Figure 11 shows the FB,KAM values alongare themostly
line from point a
point b inbFigure
in Figure 9 for9 for
thethetwo two methods.
methods. InIn finish-type
finish-type FB, theKAM
the KAM values
values are mostly fivedegrees
five degrees
tofrom
point b in
pointaato Figure
topoint 9 for
pointb.b.On the two
Onthe methods.
theother
otherhand, In
hand,in finish-type
inextrusion-type FB,
extrusion-typeFB, the KAM
FB,the values
theKAM KAMvaluesare mostly
valuesalong five
alongYYaxis degrees
axisare are
from point
from point a to point
approximately twodegrees b. On the
degrees aroundotherpointhand, and in extrusion-type FB,point
the KAM values alongindicate
Y axis are
approximately two around point aaand increasetoward
increase toward point b.b.These These findings
findings indicate that that
approximately
strainhas hasalready
alreadytwoaccumulated
degrees aroundthe point
areaawhere
and increase toward point b. Thesein findings indicate that
strain accumulated ininthe area where shearing
shearing isisgoing
going toproceed
to proceed finish-type
in finish-type FB,while
FB, while
thereisisless
there lessaccumulation
accumulationof ofstrain
strainin inthethearea
areain inextrusion-type
extrusion-typeFB. FB.As Asaaresult,
result,extrusion-type
extrusion-typeFB FBcan can
preventfracture
prevent fracturefrom fromthe theviewpoint
viewpointofofthe thestrain
strainaccumulation Observation
accumulation areaand
region
region andcrystal
crystalgrain grainphase phasefield.
field.

Observation area

Figure 8. Observation area of microgear for electron back-scatter diffraction (EBSD)

analysis.
Figure 8.8.Observation
Figure area
Observation area of microgear
of microgear for electron
for electron back-scatter
back-scatter diffraction
diffraction (EBSD) (EBSD)
analysis.
analysis.
Blanking Blanking
direction direction
Blanking Blanking
direction direction
a Scrap side a Scrap side

a Scrap side a Scrap side

b
Product side Product side b
Die
b Die
Product side Product side b
50μm
Die 50μm
Die
a) finish-type FB b) extrusion-type FB
50μm 50μm
Figure 9. Comparison of kernel average misorientation (KAM) map for 60%t punch penetration
between finish-type FB and extrusion-type FB: (a) finish-type FB; (b) extrusion-type FB.
 Figure 9. Comparison of kernel a) finish-type FB
average misorientation b) extrusion-type
(KAM) FB punch
map for 60%t
penetrationFigure
between
9. finish-type
Comparison FB of
andkernel
extrusion-type
average FB: (a) finish-type
misorientation FB; (b)map
(KAM) extrusion-
for 60%t punch
type FB. penetration between finish-type FB and extrusion-type FB: (a) finish-type FB; (b) extrusion-
Materials 2019, 12,type
2143 FB. 8 of 10

Blanking Blanking
direction Blanking direction Blanking
direction direction

Scrap side Scrap side

Scrap side Scrap side

Product side
Product side Die Product side Die
Product side Die Die

50μm 50μm

a) finish-type FB 50μm b) extrusion-type FB 50μm

a) finish-type
Figure 10. Comparison FB map for 60%t punch
of phase b) extrusion-type FB
penetration between finish-type FB
and extrusion-type
Figure 10.Figure FB:
Comparison (a) finish-type
10. Comparison FB;
of phase
of phase map (b) extrusion-type
mappunch
for 60%t for 60%t FB.
punch penetration
penetration betweenFBfinish-type
between finish-type and FB
and extrusion-type
extrusion-type FB: (a) finish-typeFB:
FB;(a)
(b)finish-type FB;FB.
extrusion-type (b) extrusion-type FB.

a) finish-type FB b) extrusion-type FB
Figure a) finish-type FB a and b of Figure
b) extrusion-type FBFB; (b)
Figure11.11.Comparison of of
Comparison KAMKAM values between
values between 7: (a)
a and b of Figure 7: finish-type
(a) finish-type FB; (b)
extrusion-type
extrusion-type FB.
FB.
Figure 11. Comparison of KAM values between a and b of Figure 7: (a) finish-type FB; (b)
extrusion-type FB.
FromFromthethe discussion
discussion in in Sections
Sections 3 and
3 and 4, 4,
wewe can
can conclude
conclude that
that thethe extrusion-type
extrusion-type FBFB process
process cancan
prevent
prevent fracture
fracture andimprove
and
From improve
the theblanking
the
discussion blanking quality
quality
in Sections bychanging
by
3 and 4,changing
we can the thematerial
material
conclude flow
flow
that during
the during the process.
extrusion-type It
FB process can
It isisa ahigh-potential
high-potential process
processfor blanking
for at
blanking the microscale.
at the However,
microscale. since
However, the material
since
prevent fracture and improve the blanking quality by changing the material flow during the process. the is compressed
material is
in the negative
compressed aclearance
It inis the negativezone inprocess
clearance
high-potential addition
zonefor to blanking
in the shearing,
addition to
at thetheshearing,
the load on the
microscale. the punch
load on
However, in the
extrusion-type
punch
since theinmaterial is
FB is higher
extrusion-type than
FB isthat in
higher conventional
than that in FB. It is necessary
conventional FB. Itto
is clarify
necessarydesign to guidelines
clarify
compressed in the negative clearance zone in addition to the shearing, the load on the punch in design for the process
guidelines
forparameters,
the process such as the optimal
parameters,
extrusion-type FBsuch negative
as thethan
is higher clearance
optimal and clearance
that negative the radius
in conventional of
It the
FB.and isthedie corner,
radius
necessary oftoin
the further work.guidelines
die corner,
clarify design
in further work.
for the process parameters, such as the optimal negative clearance and the radius of the die corner,
5. Conclusions
in further work.
5. Conclusions
An FE analysis was performed to clarify the material flow and fracture mechanism in extrusion-type
FB, in which5. Conclusions
a negative clearance was applied, in comparison with that in finish-type FB, particularly
from the viewpoint of suppressing the fracture and cracking on the shearing surface during the process.
The critical damage value, an index showing the possibility of fracture in the workpiece during FB,
was introduced as a critical fracture value. Furthermore, the SEM observation of the cross-section of
blanked workpieces with EBSD analysis was performed to confirm the results of the analysis. The
conclusions of this study are as follows:
Materials 2019, 12, 2143 9 of 10

(1) The perimeter of the workpiece under a punch flows almost perpendicularly towards the die
interior in finish-type FB. This workpiece flow behavior generates a tensile stress field between the
scrap-side workpiece (which is pressed down by the blank holder) and the blanked workpiece, with a
consequent high damage accumulation value, ultimately leading to breakage of the workpiece.
(2) In contrast, in the case of extrusion-type FB, since the perimeter of the workpiece flow under
the punch flows towards the end of the die radius, high compressive stress occurred in this region,
which led to different material flow and reduced cumulative damage.
(3) The critical damage value for extrusion-type FB was less than that for finish-type FB owing to
the difference in stress state near the shearing zone: compressive stress is dominant for extrusion-type
FB, while tensile stress is dominant for finish-type FB.
(4) The difference in strain distribution between finish-type FB and extrusion-type FB was analyzed
by EBSD. The relationship between the strain distribution and the occurrence of fracture was clarified.

Author Contributions: Conceptualization, Y.S., M.Y. and M.M.; Experiment, Y.S.; Writing—Original Draft, Y.S.;
Writing—Review & Editing, M.Y., T.S. and M.M.
Funding: This research received no external funding.
Acknowledgments: We would like to express our sincere gratitude to the members of the R&D section of our
company and also to Bastien Poitrimol, a French international student cooperating with us, for his valuable
assistance in the experiment.
Conflicts of Interest: The authors declare no conflict of interest.

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