FE Simulations and Experimental Analysis of the Blade Angle Effect on Sheared Surface in Trimming Process of Advanced High-Strength Steel Sheet

Abstract

In the precision manufacturing, the trimming process is the final step before sending a product to the surface finishing or painting. To increase the quality of trimmed parts from conventional to a high precision, the tool design is needed. Therefore, thorough understanding of tool design for making high-precision trimmed parts is a key to success. The aim of this paper is to discuss the interaction between the blade angle and trimmed clearance on the sheared surface of mild steel and advanced high-strength steel sheets in the trimming process on the basis of experimental and FE simulation analysis. In this study, three angles (0°, 30° and 45°) on trimmed punch combination with three levels of trimmed clearance (2, 5 and 10% of the sheet thickness) were proposed for producing high quality of the sheared surface. From experimental results of all material workpieces and trimmed clearances, the sheared surface increased with a change in the blade angle. The hydrostatic stress distribution in FE analysis revealed that the major mechanism of increasing sheared surface is the delay of crack propagation, resulting in high quality of trimmed parts.