Abstract
Problem statement: Sheet metal extrusion is a process in which the punch penetrates one surface of the sheet metal material to cause it to extrude and flow toward the outlet of the die. Therefore, the process can invent different thickness of sheet metal work piece. From these advantages on the sheet metal extrusion, nowadays, it is generally used in many manufacturing of industrial elements fields. The Sheet Metal Extrusions in Fine Blanking (SME-FB) advantages, over a conventional extrusion, are possible due to a blank holder force, a counterpunch force and a large die radius. However, the selection on those parameter values affects on the material flow and the surface quality on the extrusion parts also. Namely, it causes the crack surface and shrinkage failure which are the general problems in the SME-FB. Approach: Objective of this research was to study the effect of die radius on the SME-FB surface which investigated the formation of the failure defection with respect to the several die radiuses by using the Finite Element Method (FEM). Results: From the results, it indicated that applying the small die radius caused the material flow difficult resulting in the decreasing of smooth surface. Vice versa, in the case of large die radius, the material flow easy is resulting in the increasing of smooth surface. Conclusion: The FEM simulation results of a larger die radius will cause the residual stress at work piece.
Highlights
The fine-blanking process as shown in Fig. 1 is well known as an effective process to obtain the precision blanked products with a smooth and precision blanked surface
A critical fracture value was used which agree well with tensile strength and elongation between the Finite Element Method (FEM) simulation results of tensile testing and the results obtained by the experiment
As a result of this study, FEM and experimental results substantially agree well with each other, the possibility of the FEM approach is indicated for determining the optimal die design and working parameters in the Sheet Metal Extrusions in Fine Blanking (SME-FB) process
Summary
The fine-blanking process as shown in Fig. 1 is well known as an effective process to obtain the precision blanked products with a smooth and precision blanked surface. Fine-blanking process is the most popular one and characterized by three key techniques of extremely narrow clearance, die edge radius and loading compressive stress near the deformation zone with a V-ring and counter punch. This process can produce a fine cut edge without any finishing operations and is used all over the world. These advantages over conventional blanking are possible due to a very special tool design which differentiates itself from that of normal blanking which the outer periphery of the part form on the blank holder, the use of which help to prevent fracture in the part. The extra tooling and machine costs that often accompany this relatively complicated tool design prohibit the economic use of fine blanking for number of applications
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