Numerical Study of the Effect of Tool Wear on Burr Formation in Blanking Process

Abstract

Numerical simulation of the blanking process of a sheet metal, i.e. the formation of roll-over and a burnished surface, and crack initiation and propagation, is done using an elastic plastic finite element model. The Normalized Cockcroft and Latham’s expression is used as a ductile fracture criterion. Numerical study was conducted to investigate how the tool-wear affects the burr height by varying the punch nose radius. The simulation results obtained under the effect of the same process variables are in good agreement with the experimental results. Six punches with various nose edges, 0.00mm, 0.05mm, 0.10mm, 0.20mm, 0.30mm and 0.40mm were used for blanking simulations. The results indicate that the burr height is directly proportional to the punch nose radius.