Master of Simulation Techniques

Lecture No.5

„Fine Blanking“

Prof. Dr.-Ing. F. Klocke

Structure of the lecture

¾ Blanking
¾ Sheared surface and force
¾ Wear
¾ Blanking processes and blanking tools
¾ Errors on sheared workpieces
¾ Fine blanking
¾ Comparison to normal blanking
¾ Process details and degree of difficulty
¾ Tool setup and tool materials
¾ Examples of fine blanking parts
¾ Calculation of blanking processes
¾ analytical calculation method
¾ 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
¾ Blanking
¾ Sheared surface and force
¾ Wear
¾ Blanking processes and blanking tools
¾ Errors on sheared workpieces
¾ Fine blanking
¾ Comparison to normal blanking
¾ Process details and degree of difficulty
¾ Tool setup and tool materials
¾ Examples of fine blanking parts
¾ Calculation of blanking processes
¾ analytical calculation method
¾ FEA of fine blanking processes

Forms of wear on cutting punches

Structure of the lecture
¾ Blanking
¾ Sheared surface and force
¾ Wear
¾ Blanking processes and blanking tools
¾ Errors on sheared workpieces
¾ Fine blanking
¾ Comparison to normal blanking
¾ Process details and degree of difficulty
¾ Tool setup and tool materials
¾ Examples of fine blanking parts
¾ Calculation of blanking processes
¾ analytical calculation method
¾ 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
¾ Blanking
¾ Sheared surface and force
¾ Wear
¾ Blanking processes and blanking tools
¾ Errors on sheared workpieces
¾ Fine blanking
¾ Comparison to normal blanking
¾ Process details and degree of difficulty
¾ Tool setup and tool materials
¾ Examples of fine blanking parts
¾ Calculation of blanking processes
¾ analytical calculation method
¾ FEA of fine blanking processes

Geometry errors on blanked parts

Influence of the specific die clearance on the crack depth

Structure of the lecture

¾ Blanking
¾ Sheared surface and force
¾ Wear
¾ Blanking processes and blanking tools
¾ Errors on sheared workpieces
¾ Fine blanking
¾ Comparison to normal blanking
¾ Process details and degree of difficulty
¾ Tool setup and tool materials
¾ Examples of fine blanking parts
¾ Calculation of blanking processes
¾ analytical calculation method
¾ 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
¾ Blanking
¾ Sheared surface and force
¾ Wear
¾ Blanking processes and blanking tools
¾ Errors on sheared workpieces
¾ Fine blanking
¾ Comparison to normal blanking
¾ Process details and degree of difficulty
¾ Tool setup and tool materials
¾ Examples of fine blanking parts
¾ Calculation of blanking processes
¾ analytical calculation method
¾ 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

¾ Blanking
¾ Sheared surface and force
¾ Wear
¾ Blanking processes and blanking tools
¾ Errors on sheared workpieces
¾ Fine blanking
¾ Comparison to normal blanking
¾ Process details and degree of difficulty
¾ Tool setup and tool materials
¾ Examples of fine blanking parts
¾ Calculation of blanking processes
¾ analytical calculation method
¾ 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

¾ Blanking
¾ Sheared surface and force
¾ Wear
¾ Blanking processes and blanking tools
¾ Errors on sheared workpieces
¾ Fine blanking
¾ Comparison to normal blanking
¾ Process details and degree of difficulty
¾ Tool setup and tool materials
¾ Examples of fine blanking parts
¾ Calculation of blanking processes
¾ analytical calculation method
¾ 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

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

Structure of the lecture

¾ Blanking
¾ Sheared surface and force
¾ Wear
¾ Blanking processes and blanking tools
¾ Errors on sheared workpieces
¾ Fine blanking
¾ Comparison to normal blanking
¾ Process details and degree of difficulty
¾ Tool setup and tool materials
¾ Examples of fine blanking parts
¾ Calculation of blanking processes
¾ analytical calculation method
¾ 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
xg

WS = ∫ FS (x )dx cutting energy

0
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

N
qG = 20 Value of the specific counter punch force for
mm2 small sized, thin workpieces.

N
qG = 70 Value of the specific counter punch force for
mm 2 big, thick workpieces.

Calculation of fine blanking process - cutting force

FS = FSt − FG cutting force
FSt :punch force
FG :counter punch force
FS max FS max
kS = = shearing resistance
AS lS ⋅ s Fsmax :maximum cutting force
AS :shearing surface
kS
C1 = factor of shearing strength
Rm kS :shearing resistance
Rm :tensile strength
FS = l g ⋅ s ⋅τ S = C1 ⋅ l g ⋅ s ⋅ Rm calculation according to VDI-standard 3345
lg :total length of cutting lines
s :material thickness
τS :shear strength
C1 :factor of shearing strength due to
yield stress ratio
Rm :material tensile stress
0,6 < C1 < 0,9 advised value is C1= 0,9 (safety)
Structure of the lecture
¾ Blanking
¾ Sheared surface and force
¾ Wear
¾ Blanking processes and blanking tools
¾ Errors on sheared workpieces
¾ Fine blanking
¾ Comparison to normal blanking
¾ Process details and degree of difficulty
¾ Tool setup and tool materials
¾ Examples of fine blanking parts
¾ Calculation of blanking processes
¾ analytical calculation method
¾ 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 forces in
principle the tool:
stress in
blanking •blanking
punch die
and
workpiece •blank-
holder
•blanking
punch

•counter-
punch
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
¾ What does the sheared surface look like in blanking ?
¾ Why is this surface not completely smooth ?
¾ Please explain the punch force over punch travel for blanking !
¾ Why are blanking tools made of hardened and tempered material ?
¾ Why are sheet metal parts of high quantity made preferably through
blanking and not through CNC-wire Electro-erosion ?
¾ What is the maximum stroke frequency of a blanking machine ?
¾ Why is there an increased fraction of smooth surface in fine blanking in
comparison to normal blanking ?
¾ 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 ?
¾ Can hardened and annealed materials be used as workpiece material in
fine blanking ?
¾ What is the maximum plastic strain in fine blanking ?