Abstract
This paper summarizes the results of simulating the blanking process by means of a modified DEFORM-2D FEM (Finite Element Method) code. Several modifications were made to this code in order to simulate the material fracture. Unlike most other approaches, it was possible to obtain each of the zones of a blanked part edge such as roll over, shear zone, rupture zone and burr. Several blanking simulations were performed and the results were compared with our experimental studies. It was shown that the influence of process variables such as punch-die clearance, material properties and punch and die wear could be simulated with a good correlation to experimental results. Furthermore, the simulated and experimentally obtained load stroke curves show the same changes of shape and absolute value due to variations in process conditions.
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