Numerical Simulation And Control Of Burr Formation Process In Blanking Of Sheet Metals

Blanking technology is a basic method of metal plastic processing.It is used to made many kinds of sheet metal parts with the characteristics of higher production efficiency,better dimensional accuracy,lighter weight and easily to realize mechanization and automation.The edge of parts formed in the sheet metal blanking process consists of the fillet zone,the smooth zone,the fault zone and burr which is the most important factor for edge quality.So it is effective for improving edge quality to restrain and reduce burr.With the improvement of the demands in the blanking part quality,the research on the mechanism of burr formed in the blanking process and the measure about reducing burr are paid more and more attention by domestic and foreign scholars.The main work of this paper is described as following.(1) On the base of mechanical foundation of plastic deformation,the force condition in deformation zone is analyzed in this study.Moreover,this paper has also expounded the basic law of crack propagation and the mechanism of burr formation.(2) The plastic analysis soft ware DEFORM-2D was used to simulate the low carbon steel AISI1010 from which the stress and strain distribution of material in the blanking process had been obtained and established flow model.The result show that in the blanking process the material affected by tensile stress was forced to flow into deformation zone which caused cold-work hardening,made burr hardness reach to the maximum and the fracture damage value in deformation zone was also reached to the maximum.(3) By means of finite element method(FEM) and experimental measure,the influencing factors of edge quality of blanking part(mainly burr height) have been analyzed in this paper.Along with the increased blanking clearance,blanking burr height increases at first and then decrease.Moreover,blanking burr height increased by linear as the die wear loss increasing.All of those are keep consistent with simulation analysis.(4) According to mechanism,character and type of blanking burr of sheet metal, the control method and removal measure of blanking burr of sheet metal are advanced.The generation mechanism and influencing factors of blanking burr are deeply researched in this paper,with the research field of blanking widened which has theoretical value and practical value.