Study of Blanking Process with V-Ring Using Experiment and Finite Element Method

Abstract

A fine blanking process produces smoother surfaces finish than a blanking process because of a higher tri-axial compressive stress caused by v-ring and smaller punch-die clearance. This work aims to study the effect of the added v-ring design parameters on the blanking process of the SPCC sheet. Three dimension and two dimension finite element models of blanking process were used for studying the effect of v-ring design parameters on the cutting force and the quality of the surface edge respectively. The FE model of the blanking process of an isotropic elastic-plastic with ductile fracture criteria material was validated with the SPCC blanking experimental tests and the results agreed well. The influence of size and shape of v-ring on cutting forces and surfaces edge were examined using Taguchi method. Four v-ring design parameters, namely the height, the radius, the angle and the distance between die and v-ring were investigated. The Taguchi main effect analysis and ANOVA results show that the distance between die edge and V-ring is the most important factor for cutting forces. The radius of v-ring edge is the most significant factor for the length of smooth-surface and the angle of V-ring is the most important factor for burr heights.