Abstract
An extrusion-type fine blanking with a negative clearance was proposed by the authors instead of standard fine blanking for creating a full-sheared surface in the micro blanking process. In this study, micro blanking experiments and finite element analyses with narrow, zero and negative clearances are carried out for the optimizing the clearance at which a shear cut surface can be finished with a full-sheared surface with the minimized punch load. Fracture criterion, hydrostatic stress and maximum punch stress for the conditions with various clearances are investigated. As a result, it was clarified that the clearance at which the cut surface does not fracture and minimization of the punch load is achieved is gained by the use of clearance −4 μm.
Highlights
In recent years, attention has been paid to micro-processing technologies suitable for mass production
An involute tooth profile part with a microsize and a complicated shape was selected as a representative example of a microsize part, and the so-called fine blanking (FB) [8,9] for the effect of hydrostatic pressure on the ductility of the metal [10], was used
The results revealed that it was possible to process full-sheared surfaces by adopting negative clearance [11]
Summary
Attention has been paid to micro-processing technologies suitable for mass production Problems, such as the lowering of material forming limits due to thinner materials [1,2,3,4] and the lowering of dimensional accuracy (e.g., the fracture that occurs on the cut surface during shearing) due to the downsizing of product dimensions, have not been solved. Various research studies have been conducted on manufacturing methods for the microfabrication of small parts, such as laser processing, etching processing, and electron beam processing [5,6,7]. These microfabrication methods are not necessarily optimal from the viewpoint of productivity and cost. The finite element method (FEM) and material crystal analysis by Electron Back Scatter Diffraction (EBSD) have revealed the difference in the processing mechanism between the two FB methods [12]
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