The Simulation And Experimental Research Of Fine-Blanking Technics Based On Adjustable Suspending Fine Blanking Die Holder

Fine blanking is an advanced metal sheet forming technique, which is developed from traditional blanking process, it has characteristics of good quality , high efficiency, low cost and wide range of use. Parts produced with fine blanking can be directly used for assembling for its high dimentional accuracy and glabrous blanking section, Therefore, production cost can be reduced for saving subsequent processing . Currently, Fine blanking technique has been broadly used in various fields everywhere in the world, development of this technology is becoming an urgent requiement for industrial progress. Research work have been carried out in our country since 1965 and also some achievements have been made in this area, however, applications of this method in our country are still in a relatively under-developed stage due to restrictions of all sorts of conditions, especially, the high price of imported equipment limitted its popularization. According to the situation of our country, the priority in our development strategy of fine blanking at the present time is to research fine blanking equipment with low cost , high efficiency and powerful practicability.Powerful pressing plate fine blanking is a process in which the material's deformation zone keeps in a three-dimensional state of stress and material split apart through the plastic shear deformation under the condition of no occurrence of cracks. In this case , three kinds of forces must be provided synchronously by the woking equipment in order to maintain the three-dimensional state of stress in the deformation zone. It is difficult to accomplish this process on an ordinary forcing press, so , researching and developing fine blanking die carrier and making it possible to actualize fine blanking on an ordinary forcing press have got to be one aspect of the development of fine blanking technique. Upright post guided fine blanking die carrier was thus devised and populary used under these circumstances, but the structure of this kind of die carrier is confined by working surface of table, therefore, it can't implement multi-position blanking and punching in the different section on one sheet material. Moreover, shortcoming of declined precision become visible with the development of clearance which is caused by abrasion wear between the guide bushing and the guide pin. In order to solve above-mentioned problems, Professor Song Yuquan with Superplatic and plastic research institute of Jilin University, applied for a national inventive patent "Adjustable suspension fine blanking die carrier ", this kind of die carrier has advantages of multi-position, high precision and long service life. The carrying out of this thesis is just based on aforementioned fine blanking die carrier.On the basis of consulting plentiful technical data in regard to fine blanking, a fine blanking process for a typical disc-shaped part is selected as the object of study in this paper, pre-requisite theoretical principle of finite element for computer simulation is concisely introduced, the characteristic and function of simulation software DEFORM are summarized and analysed, and then the fine blanking process for a disc-shaped part is simulated using the software DEFORM. Subsequently, actions of principal process parameters namely, blanking clearance, dimension of blank holder, blank holder force and counterpressure during the fine blanking process and the influence of different process parameters on the forming results are analysed. Finally, according to the finite element analysis result, experimental verification of the process parameters is made.The workflow of this paper is as follows: (l)Achieving the initial process parameters (blank holder force, counterpressure, blanking clearance, gear ring parameter) utilizing fine blanking handbook; (2)Drawing the three-dimensional fine blanking model using the modeling software CATIA; (3) Importing the model to the finite element simulation software DEFR0M-3D and then making simulation; (4) Analysing the simulation result; (5)Through the analysis of the simulation result, adjusting correlative parameters quantificationally, making simulation once more; (6) Making comparative analysis on the simulation results attained from different parameters and finding out the most appropriate parameters; (7) On the basis of last procedure, designing major parts of the punch die(male die, female die, heavy duty blank holder), drawing up the process and making fine blanking simulation.The research result shows that, using finite element software DEFR0M-3D to make the simulation of fine blanking, through the comparative analysis on the simulation results attained from different parameters, combinning the principle of fine blanking and the analysis of mechanical model, getting the influence of each parameter on the processed part, seeking proper process parameters in the light of of its specific requirment of the formed part, will greatly shorten the time needed for die designing, reduce experiment cost. This will play an important instructional role in practical production.The adjustable suspension fine blanking die carrier satisfies the anticipated design requirement and has mighty practicability.