Abstract
The process behavior in the punching of holes in a larger thickness circular steel plate using punches of different outer diameters, convex double-shear angles, convex lengths, and surface treatments was investigated. Experimental results showed that the appearance of the punched hole for a small clearance between the punch and the die displays a great number of slips to extend almost to the end of the hole through shear. When punches of convex double-shear angles of 20° with surface treatment are used, the straightness and surface finish of the punched hole show a better state. The worn conditions of the punch during shearing can be broadly classified into side wear, face wear, chipping, crack, and gross fracture. The failure mode of a punch with a convex double-shear angle of 12.5° during the piercing holes was mainly side wear. In addition, the worn mode for a punch of a convex double-shear angle of 20° shows dominantly side wear and gross fracture. The tool life for a punch having a convex double-shear angle of 20° is greater than that for a punch of 12.5° convex double-shear angle. The effect of the convex length of the punch on the tool life for a convex double-shear angle of 20° is significant. In addition, the tool life for a punch with a TiC coating or lapping treatment is greater than that of a punch without surface treatment by 25–60%.
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