| Blanking is one of the basic method of metal plastic forming,the area of blanking deformation is concentrated in the narrow die clearance,and blanking is intricate because the analysis of the blanking needs to consider material nonlinearity,contact condition nonlinearity and geometrical nonlinearity.Blanking punch can generate fatigue fracture in the process of continuous stamping and it can aggravate die wear,and it makes the height of burr over the design requirement.In addition,it will reduce the service life of the mold and increase the production cost of the enterprise.With the rapid development of finite element simulation technology,finite element software is used to simulate the fatigue life and die wear of punch,and the conclusion has an important guiding significance on the production of enterprise.Transmission strap is taken as the research object in this paper,ANSYS Workbench software is used to optimize the structure of the blanking punch,and the progressive die of transmission strap is designed to verify the simulation.In addition,DEFORM-3D is used to simulate the blanking process and die wear of sheet metal(the material is CK75 and the thickness is 1.1 mm),and the relationship between process parameters and punch wear is studied.And process parameters of blanking is optimized based on orthogonal experiment,the main research can be summarized as follows:(1)The blanking process of sheet metal is analyzed,and the friction of the sheet metal blanking deformation zone is studied,the wear process and the influencing factors of die wear are introduced.In addition,the key techniques of simulation for the optimization of the structure and the wear of the blanking die are introduced.(2)The finite element model of fatigue life for transmission strap is established,finite element software of ANSYS Workbench is used to optimize the structure of punch.The progressive die of transmission strap is designed based on the process analysis of parts,and it is used to verify the fatigue life of punch after optimization.(3)The finite element model of die wear for transmission strap is established,DEFORM-3D is used to simulate the die wear in blanking process of CK75 at 1.1 mm,and the relationship between the die clearance,the radius of the die,stamping speed and the wear depth of the die is studied.Orthogonal experiment is applied to simulate die wear of transmission strap at different process parameters,it is concluded that die clearance has an significant influence on the punch wear by variable analysis,and the sequence of influencing factors is die clearance,radius of die and stamping speed respectively.In addition,the optimized combinations are achieved for the blanking of transmission strap by orthogonal experiment.(4)Experiment of blanking for transmission strap is designed based on response surface methodology,the mathematical model between process parameters and wear depth of punch is established according to the simulation experimental results.The results show that the mathematical model of response surface methodology can be used to establish the relationship between the process parameters and the punch wear,the radius of punch and stamping speed have the most interactive effect on the punch wear. |
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