The Simulation Of The Fine Blanking Of Steel Back Plate Without Gear Ring And Optimization Of Process Parameters

As a very important part of the vehicle brake system, automotive friction brake block has become the umbrella of the people and cars because its quality has a direct impact on vehicle braking performance. However, the quality of the brake is subject to the quality of steel back blanking surface. The current steel back production mainly uses conventional blanking technology, its punching surface inevitably appear a large number of fracture surface and burr, and causes the brake noise, poor braking effect and lower punching surface hardness. If use precision blanking, it not only increase the production equipment investment, but also greatly increase the cost of multi-model, small quantities of steel back, so reduce the competitiveness of the products. At present, the enterprise manufacturers realize the fine blanking of steel back plate without gear ring through the modification of ordinary press, making the above problem solved. However there is still no technical guidance for this technology, so depend only on experience to commissioning is difficult to obtain reasonable parameters. Therefore, developing the technology of the fine blanking of steel back plate without gear ring, summing up the influence law of the shape of steel back and process parameters undoubtedly has important practical significance.According to the fine blanking technology principles, this paper solved the relation of the hydrostatic pressure in fine blanking without gear ring deformation region and the external forces, and analyzed the impact factors of the hydrostatic pressure from a theoretical point. At the same time the blanking surface of fine blanking was analyzed, and the collapse angle face of fine blanking and the cause and its influencing factors of the burr were obtained. And then built3D model of the fine blanking of steel back plate without gear ring by pro/E software, and then imported into DEFORM-3D simulation software to build the numerical simulation model of the fine blanking of steel back plate without gear ring.Steel back plate is a non-symmetry plate with complicated shape. In fine blanking without ring gears, shape has a great influence on the quality of fine blanking product. According the DEFORM-3D numerical simulation results, the effect of steel back plate’s shape on the distribution of hydrostatic stress in deformation area was investigated in this paper. And the percentage of the collapse surface, bright surface and fracture surface in different shape area was observed. The results offered basis for further analysis on process parameters’effect. By setting different process parameters, the law of effect of blank holder force, blanking clearance, die fillet and counterforce on the quality of fine blanking was investigated. Data shows that the four factors have great influence on fine blanking without ring gears. According to the results, the best process parameter in every single factor can be obtained which can provide a process optimization on blank holder force, blanking clearance, die fillet and counterforce by using orthogonal test method, and also the effect order of these four factors on fine blanking and the best combination of process parameters.