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© WZL/Fraunhofer IPT
Blanking and Fineblanking
Simulation Techniques in Manufacturing Technology
Lecture 5
Laboratory for Machine Tools and Production Enginee ring
Chair of Manufacturing Technology
Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. F. Klocke
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Calculation of blanking parts5
Fineblanking4
Shearing3
Requirements on blanking parts2
Introduction1
Outline
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� Deep Drawing� Ironing� Spinning� Hydroforming� Wire Drawing� Pipe Drawing� Collar Forming
Casting Forming Cutting Joining Coating Changing of Material Properties
Compressive Forming
Tenso-Compressive
Forming
Tensile Forming
Bend FormingShear
FormingSevering
� Translate� Twist� Intersperse
Manufacturing Processesaccording to DIN 8580ff
� Open DieForging
� Closed Die Forging
� Cold Extrusion � Rod Extrusion� Rolling� Upsetting� Hobbing� Thread Rolling
� Stretch Forming� Extending� Expanding� Embossing
� With linear Tool Movement
� With rotating Tool Movement
� Shearing� Fine Blanking� Cutting with a
single Blade� Cutting with
two approaching Blades
� Splitting� Tearing
Introduction
Sheet Metal Forming Processes
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Introduction
What is blanking?
� Definition :
Mechanical separation of workpieces by a shearing process without formation of chips –if necessary, including additional forming-operations.
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Calculation of blanking parts5
Fineblanking4
Shearing3
Requirements on blanking parts2
Introduction1
Outline
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Requirements on blanking parts
Required quality of blanking parts
surface evenness
smooth sheared zone
cutting burr
rupture zone
draw-in
achievableroughness
angular deviation
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Calculation of blanking parts5
Fineblanking4
Shearing3
Requirements on blanking parts2
Introduction1
Outline
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Shearing - Introduction
Shearing – Introduction
application IT-classification costs output
Shearing
high
rough (IT 11) low high
lowfine (IT 7)
sheared surface
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Shearing - Characterisation of the process
Open and closed cut in shearing
open cut closed cut
tool flank open flank
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Shearing - Characterisation of the process
Differentiation of blanking and piercing
blanking piercing
waste
waste
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Shearing - Characterisation of the process
Tool design of shearing
punch
sheet metal
blanking die
u – die clearenceapp. 0,05 x sheet thickness
with:u = ½ · (a – a1)
a – dimension of cutting die
a1 – punch dimension
α – relief angle of cutting die
U
blank holder
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Shearing - Characterisation of the process
Process sequences of shearing
1 2
3 4
charging of the punch
elastic & plastic deformation
shearing & cracking
break through
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Shearing – Achievable accuracy
Errors on sheared workpieces
burr height h G
draw-in height h E
draw-in
shearing zone
rupture zone
tR
hG
hE
crack depth t R
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Shearing – Achievable accuracy
Influence of die clearance on the sheared surfaces
small clearance
big clearance
� By a small die clearance, distortion wedges are generated by squeezing of the material between two cracks
no formation of distortion wedge
formation of distortion wedge
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Shearing – Achievable accuracy
Quality of sheared surface depending on specific di e clearancesp
ecifi
c di
e cl
eara
nce:
di
e cl
eara
nce
u S/ s
heet
thic
knes
s s
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Shearing – Achievable accuracy
Influence of specific die clearance on crack depth
blanking
specific die clearance u s / %
Cra
ck d
epth
tR
shee
t thi
ckne
ss s
Part diameter da = 30 mm
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Shearing – Achievable accuracy
Relation between burr height and number of cuts
ductilesheet
brittlesheet
burr height
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Shearing - Forces in shearing
Reduction of cutting force by modification of tools
Contact between punch and sheet
slopedcut
planecut
s h
total punch strokefo
rce
F
0 s 2s 3s
0,3 Fmax
0,6 Fmax
0,9 Fmax
Fmaxh = 0 (plane cut)
h = 1/3 s (sloped cut)
h = s (sloped cut)
h = 2s(sloped cut)
=
work s(h=0) = work s(h=2s)
� Due to workpiece-bending, sloped cut is only suited for piercing.
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Shearing - Forces in shearing
Reduction of cutting force by modification of tools
conical punchgrooved punchplane cut sloped cut
conical die grooved diepunch offset
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Shearing - Forces in shearing
Dependence of quality on shearing strength of carbo n steel
carbon concentration tensile strength breaking elongation sheet thickness
die clearance part diameter aspect ratio Die / punch radius
� Cutting resistance kS is defined as the cutting force (Fs) referring to the cutting surface kS = FSmax / AS (with As= ls*s)
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Shearing – Wear
Wear on the punch
wear on shaft area
wear on front facefatigue wear on front face
� fatigue wear and wear on front face especially appear for lower sheet thickness (s < 2 mm)
� wear on shaft area – is caused by friction between
punch and sheet in direction of punch movement
– appears during cutting of thicker sheets (s ≥ 2 mm)
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open cut
Workpiece
Shearing – wear
Influences on wear
Source: reiner, Müller Weingarten, Feintool
Tool Machine
Type of process
tool wear
materialhardnesssurfaceguidancedie clearance
stiffnesskinematics
alloystiffnesshardnessdimensionshape
open cutclosed cut
closed cut
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Shearing – Tool design
Multi-stage blanking tool
4 stage Multi-stage blanking tool for shearing of rotor- and stator-sheets
stator rotor
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Calculation of blanking parts5
Fineblanking4
Shearing3
Requirements on blanking parts2
Introduction1
Outline
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Fineblanking - Introduction
Fineblanking - Introduction
application IT-classification costs output
shearing
fineblanking
high
rough (IT 11) low high
lowfine (IT 7)
sheared surface
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Fineblanking – Characterisation of the process
Animation of fineblanking
clamping
plastic deformation
cutting
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fineblankingshearing
1 – cutting die(2 – guiding plate)3 – punch
FS – punch force
1 – cutting die2 – vee ring and
blank holder3 – punch4 – counter punch
FS – punch forceFR – vee ring and blank
holder forceFG – counter punch
force
Fineblanking – Characterisation of the process
Differences between shearing and fineblanking
die clearance5% 0,5%
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Fineblanking – Details
Geometry of vee rings
thin sheets
thick sheets
sheet thickness s5 – 15 mm
sheet thickness s3 – 5 mm
blank holderwith vee ring
cutting die
• create compression stresses• prevent horizontal movement of the
sheet / material flow
vee ring
cutting line
toothed
inward notch
outward notch
vee ring cutting line
intention :
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Fineblanking - Details
Dependence of workpiece quality on influencing quan tities
counter punch force draw-in width draw-in height
smooth shearingzone
deflexion
Process parameters affect workpiece quality:example:
draw-in height die clearance sheet thickness
blank holder forcecounter punch force
Workpiece quality can be influenced by process para meters:example:
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Fineblanking – obtainable precision
Definition of degree of difficulty in fineblankingsl
ot a
, stic
k b
/ mm
sheet thickness s / mm
edge
rad
ius
ri ,
ra
/ mm
sheet thickness s / mm
degree of difficulty
S1 – easy
S2 – mediumS3 – difficultedge angle a
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Fineblanking – comparison of techniques
Comparison of sheared surface in shearing and fineb lanking
shearing
fineblanking
� In fineblanking, the smooth sheared zone can take a share of 100%
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Fineblanking – application
Application examples
fineblanking
shearing
� In fineblanking, the sheared surface can be used as a functional surface
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Fineblanking – Field of application
Application examples in automotive industry
valve plate
gear shifting gate door lock window lift
synchronising disc
belt pretensioner
ABS-pulse generator
cooling systemseat belt componentsseat adjustment
brakes
gear
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Calculation of blanking parts5
Fineblanking4
Shearing3
Requirements on blanking parts2
Introduction1
Outline
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Calculation of blanking process
• Analytical calculation method
• FEA of (fine)blanking processes
Principals and drawbacks
Advantage over analytical calculation by means of examples
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Calculation of blanking process - cutting force
SSS klsF ⋅⋅=max
mS Rk 8,0=
maximum cutting force
s :sheet thicknesslS :length of cutting linekS :cutting resistance
approximate calculation with tensile strength
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Calculation of blanking process - cutting energy
( )∫=gx
SS dxxFW0
maxSgS FxcW ⋅⋅=
cutting energy
x :cutting distanceFS :current cutting force
c :correction factorincluding variables like material properties, effective cutting distance, size of die clearance and friction
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Calculation of fine blanking process - vee ring forc e
mRRR RhlF ⋅⋅⋅= 4 approximation value for the vee ring force
lR :length of vee ringhR :overall height of vee ringRm :material tensile strength
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Calculation of fine blanking process - counter punch force
GqG qAF ⋅=
220
mm
NqG =
270
mm
NqG =
Approximation for the counter punch force
Aq :cutting piece surfaceqG :specific counter punch force
Value of the specific counter punch force for small sized, thin workpieces
Value of the specific counter punch force for large, thick workpieces
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Calculation of fine blanking process - cutting force
GStS FFF −=
sl
F
A
Fk
S
S
S
SS ⋅
== maxmax
m
S
R
kC =1
mgSgS RslCslF ⋅⋅⋅=⋅⋅= 1τ
9,06,0 1 << C
cutting force
FSt :punch forceFG :counter punch force
Fsmax :maximum cutting forceAS :shearing surface
factor of shearing strength
kS :shearing resistanceRm :tensile strength
calculation according to VDI-standard 3345
lg :total length of cutting liness :material thicknessτS :shear strengthC1 :factor of shearing strength due to
yield stress ratioRm :material tensile stress
shearing resistance
advised value is C1= 0,9 (safety)
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Simulation fine blanking
Simulation of fine blanking offers the opportunity to include:
This leads to the following results:
• force over punch travel• stress field• strain rate field• draw-ins• prediction of fracture
• flow stress data• friction properties• thermomechanical coupling
More exact input data can be enclosed:
instead of mgS RslCF ⋅⋅⋅= 1
.constRm =