Research On Fine Blanking Process For A Type Of Flange Parts Of Automobile

Flange plate in vehicle is a type of part which has convexity edge. it is play a important role in a car. Fine-blanking is an effective and economical metal cutting process which offers a precise and clean cutting edge finish ,eliminates unnecessary secondary operations, ensures complete and repeated batch accuracy ,reduces the need for time-consuming inspection, increases quality ,improves hardness along the blanked, coined areas, compresses grains along the blanked area and produces a homogeneous skin-hardened structure by triple forces ,etc. Fine-blanking results in big substantial savings and is now widely applied in manufacturing industries all over the world.Fine-blanking traditional process is very complicated, so it is necessary to develop a new and a simple process to replace the tradition complicated process partly in the factory which not equipped the very expensive triple action presses, this limit it's application. Fine blanking process with tool of stepped edge can implement on common press.Fine blanking process with tool of stepped edge needn't the indented V-ring, instead of it, there is a flat indented plate. The process only through the negative clearance on the punch or die to generate a compressive stress state in the deformation area. This makes the fine blanking process very simple, feasible, and economical. The principle of this process is similar to the traditional fine-blanking process with indented V-ring, but the research and application in industry of this process is hardly visible.In this paper, a method was used which combined finite element method and experimental method. The fine-blanking process with tool of stepped edge was systemic researched. The reasonable region of the parameters matched was obtained and made this process valuable for industrial application. According to a practical flange , reasonable processes was given.An updated Lagrange large deformation finite element method was used .Though the finite element simulation, present the process of the fine-blanking with tool of stepped edge ,show the deformation and sheet metal material flow of process of fine-blanking ;Analyze the stress and strain state, and though this analysis to guide to define the geometrical parameters of the design of the tools ,and the reasonable range of the geometrical parameters of tools was given; Analyze the affect of geometrical shape of the tool for fine-blanking quality and the maximum force calculate function of the punch was obtained; The theoretical conclusions above all ,successful applied in a practical flange. To validate and supplement the finite element analysis results ,three models was designed and the experiments has been carried out, the results is consistent with the finite element simulation.