Analytical and Experimental Investigation of Product Geometry and Dimensional Accuracy in the Punching Process of AA 1050 and AA 1070 Sheets

Abstract

Punching is a widely used and economic manufacturing method that needs to be addressed. Especially the forces that occurred during punching and the dimensions of the parts obtained from punching are important in manufacturing processes. This study aimed to examine the cutting forces that occur in the punching process and the dimensional accuracy of the parts. AA 1050 and AA 1070 sheet materials were used in the experimental studies. Five punches with different tip geometries were used in the punching processes. Punching operations were carried out at a constant clearance value and press speed. The geometries of the specimens obtained from the experimental studies were examined using stereo and shuttle-pix microscopes. In addition, punching processes were also investigated using the finite element method. The consistency of the finite element model was analyzed by comparing experimental and numerical studies. The highest cutting force occurred in the use of the flat punch geometry. The lowest cutting force was obtained by using the largest angled punch geometry. It has been determined that the dimensional accuracy of not only the blank but the falling part is better in the use of the flat punch geometry comparing the other punches used. In addition, it was observed that experimental and theoretical studies are compatible with each other. It is thought that finite element software can provide time and cost savings in determining the cutting force of materials.