Process Analysis Of Thick Plate Fine Blanking And Research On Die Cutting Edge

The fracture zone of fine-blanked surface is an important indicator to measure the quality of parts.The fracture zone reduces the effective use area of the fine-blanked surface,and leads to the poor quality of parts.The fracture is particularly serious during the fine blanking process of thick plate,which is a major problem in the actual production of enterprises.To solve the problem,the finite element model was established by software DEFORM-2D to discuss the influence of the main process parameters on the quality of parts.And a new type of composite chamfering die cutting edge was designed,which can effectively control the fracture of thick plate parts and obtain a completely smooth fine-blanked surface,and it had been verified in the actual production of the fine-blanked parts.Firstly,finite element(FE)analysis was performed to investigate the influence of the main fine-blanking parameters(i.e.,blank holder force?counter force?coefficient of friction?die clearance?die radius)on the quality of the fine-blanked parts.The combination of the Taguchi method and the analysis of variance(ANOVA)techniques was an effective tool to predict the degree of importance of each process parameter on the quality of the fine-blanked parts,which can provide direct guidance for the actual fine blanking production.Secondly,a new type of composite chamfering die cutting edge was designed,then orthogonal FE simulation experiments were carried out to investigate the influence of each geometric parameter of the cutting edge on the quality of the fine-blanked parts.By analyzing the material flow and fracture behavior during the fine blanking process,the appropriate compound chamfer parameter window was obtained,and the load of the die and the wear life has been investigated in a finite element analysis by a rigid–plastic FEM code,DEFORM-2D.Thirdly,a three-dimensional simulation model was carried out to investigate the influence of the part contour shape on the quality of the fine-blanked parts.By setting different die clearance and different die radius on different contours,the quality of the fine-blanked parts can be improved.And the FE simulation results indicated that a V-ring at the die edge can significantly reduce the die roll of fine-blanked parts.Finally,the finite element model was established by software ABAQUS to analyze the forming process of actual fine blanking fork parts,find the cause of the problems and propose optimization plans.The compound chamfering die edge was applied to the actual production of parts,and there was significant agreement between simulation result and actual production.