Finite Element Simulation Of Die Wear And Its Life Analysis In Thick Plate Blanking

As the continuous development of manufacturing industry,blanking process is more and more widely used because of its high production efficiency,simple operation,no cutting or less cutting.At the same time,people’s quality requirements of blanking products are also getting higher and higher,in order to ensure the blanking quality,the studies of blanking process,blanking die wear and its life are also getting more and more important.Busbar which usually made of thick copper plate is a commonly used part in the switch cabinet,and blanking is one of its most important procedures.This dissertation takes copper busbar’s blanking process which thickness is 8mm,circular hole diameter is 9mm as the research object,analyses blanking process and die wear through theory and simulation,and using the cumulative wear method which based on finite element establishes the wear prediction model of blanking,as compares with the actual wear situation of the factory,verifies the accuracy of the model.The main contents of this dissertation are as follows:First of all,according to the relevant contents of plastic forming theory,this dissertation analyses the blanking process,both force condition and stress state of busbar and die;the failure mode of die is summarized,mostly on wear failure’s theory,type and mechanism.Secondly,this dissertation introduces the finite element theory and DEFORM software briefly.Dissertation also builds the finite element model through DEFORM software according to the actual blanking process of factory,and sets the related parameters,dissertation combines simulation and experiment to determine fracture criterion’s parameters.After the simulation,dissertation analyses the fracture surface of workpiece,the blanking force,the wear and stress of die,finds that result is similar compared with experiment.As the wear of punch is much bigger than bottom die,so dissertation analyses die wear only takes punch as an example in the following section.Then,dissertation analyses the influence of some factors with different parameters to the punch wear,the length of the fracture zone and the maximum blanking force.In the selected range of parameters,the wear increases with the increase of blanking speed,punch edge radius and friction coefficient,decreases with the increase of die clearance and die hardness;besides the increase of cutting edge radius will make the fracture zone length increase firstly and then tend to a steady trend,other factors have no obvious direction influence for its length;besides the increase of die clearance will make the maximum blanking force have a slight decrease trend,other factors won’t have an obvious influence on its maximum blanking force.In the dissertation,the wear effects of the die with the selected factors’ different parameters are sorted through orthogonal test,the order is punch edge radius,die hardness,blanking speed and blanking clearance.In the end,the dissertation summarizes the common life prediction methods of die,and predicts the blanking die’s life based on the cumulative wear finite element method,gives the variation curve of punch wear profile during its life.The punch which achieved service life both in simulation and reality,their results of wear profile and blanking burr are similar,so the prediction model is accurate and feasible,and can provide reference for the process parameters optimization,stress analysis and life prediction.