Research On Computer Simulation Of Thick Plate Fine-Blanking And Optimization Of Die Edge

Many products obtained by thick plate fine-blanking technology have not only the adequate strength and rigidity, but also the lower cost and longer useful life. The technology has been widely used in many fields, such as heavy duty car, agricultural machinery, engineering and constructional machinery. However, there are some problems in the fine blanking process, such as a tough working condition of the punch, a short life of the die and a poor quality of blanked parts. The thick-plate fine blanking process is very complicated since the deformation is focused on the small zone of the sheet metal and ended with fracture occurrence, and there are many theoretical problems to be solved, which limit the wide application of this technology. As a major developing direction and an important project, the thick-plate fine blanking technology catches the attention, and the corresponding theoretical studies are significant increasingly.The parameters affecting the material plasticity flow in the process of fine blanking and deformation from the perspective of plasticity mechanics were analyzed, and the various ways increasing static hydraulic pressure in the deformation area were researched. Based on the stamping theory, the thick-plate fine blanking process was analyzed and the main factors affecting quality of cross-section of the blanked parts were summaried up. With rigid-plastic finite element method, a reasonable finite element model of the fine blanking was built, and its numerical simulation was carried out. DEFORM-3D was used to simulate the deformation process of the fine blanking of AISI-4140 with the thickness of 6mm in order to acquire the stress and strain fields during the deformation process. The cross section quality and the blanking pressure change were analyzed by altering the technical parameters, such as blanking gap, the plate thickness, blank holder-pressure and anti-pressure.DEFORM-3D was used to simulate the blanking process and a scheme of waved-edge fine blanking was presented. The rules about the waved-edge influence on the quality of the cross-section and blanking force were obtained by comparing the waved-edge blanking and flat-edge blanking.The research results indicate that, the blanking force increases with the increase of the plate thickness. The proper increase of the blank holder-pressure and anti-pressure can help to improve the quality of the cross-section. However the increased blanking force caused by the increased anti-pressure can shorten the die mould life. Waved-edge fine blanking technology is an effective way to reduce the blanking forcein the usage of the thick plate blanking.