Analysis of fine blanking process through finite element simulations

ABSTRACT

Fine blanking is a widely used process in the automotive industry to produce different parts in mass production. In blanking, the quality of the final product mainly depends on process parameters. The present paper is focused on developing the finite element model for the blanking process to study the effect of process parameters on the quality of the blanked part. The finite element model has axisymmetric quadrilateral elements with an automatic mesh adaptivity feature. The effect of clearance, punch/die corner radius, and binder type on plastic flow, punch forces, and die rollover has been studied through FE simulations. The FE results reveal that die rollover height and die rollover depth is increasing with the increase in clearance. The V-ring binder is decreasing the die rollover over the flat binder. The punch force is not effecting much with the clearance between die and punch. The developed FE models can be used to improve the robustness of the process and process optimisation to enhance the quality of the blanked parts.

KEYWORDS:

• Fine blanking
• finite element simulations
• clearance
• die rollover
• effective plastic strain

Acknowledgments

The authors would like to thank Mr. Arun Karthik for providing the support to access the software to carry out the simulations.

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Funding

Presently the work has not been funded.