Blanking Process Research Articles

ПЛАНИРОВАНИЕ ПРОИЗВОДСТВЕННОГО ПРОЦЕССА МЕХАНИЧЕСКОЙ ОБРАБОТКИ БРУСОВЫХ ЗАГОТОВОК КАК ЭЛЕМЕНТ ПОВЫШЕНИЯ ЭКОНОМИЧЕСКОЙ БЕЗОПАСНОСТИ ПОДРАЗДЕЛЕНИЙ УГОЛОВНО-ИСПОЛНИТЕЛЬНОЙ СИСТЕМЫ

The article examines the issue of planning production activities at woodworking enterprises in the industrial sector of the penal system. The organization of planning of production and economic activities based on the requirements of the penal enforcement legislation is considered. A conceptual scheme for planning the process of mechanical processing of timber blanks has been developed. The place of effective planning in the overall strategy of ensuring the economic security of the industrial sector of the penal system is shown.

PROSES PEMBUATAN BRACKETBRAKE PEDAL STOPPER TYPE SU2ID MENGGUNAKAN MESIN STAMPING PRESS

AbstractPersada Selaras Indonesia is a company operating in the field of stamping and die sheet metal in Majalengka Regency. One of the products produced at PT. Persada Selaras Indonesia is part of the Brake Pedal Stopper Bracket. In the process of making Brake Pedal Stopper Bracket Parts using SAPH-440 material using a Press Stamping Machine with a capacity of 110 Tons through the Dies selection process for the Blanking, Bending (1 + 2), and Pierching processes. Researchers used the observation method to determine the process of the Brake Pedal Stopper Bracket Part. The Brake Pedal Stopper Bracket Part is one of the components contained in the brake pedal of the Hyundai Creta vehicle which is produced at PT. Persada Aligned Indonesia. The process of making Brake Pedal Stopper Bracket Parts is divided into several parts, namely the Planing process, Shearing, Blanking Process, Bending Process (1 + 2), Pierching Process, and Quality Control Process. Keywords : SAPH-440, Press Stamping Process, Part Bracket Brake Pedal Stopper

The influence of cutting mode elements on the technological parameters of the process of milling blanks of titanium alloy thin-walled parts

The purpose of a rational mechanical processing mode remains an urgent task of pre-production engineering. Known recommendations and methods for selecting this mode are focused on the processing of solid blanks and do not take into account the fact that when processing thin-walled blanks, the temperatures in the processing zone and the surface layer of the blank differ. The study is aimed at identifying patterns in changing the parameters of the milling process of thin-walled blanks depending on the mode elements, as well as developing recommendations for selecting this mode. The authors performed numerical simulation of technological parameters of the milling process of solid and thin-walled blanks made of titanium alloy under various modes. The cutting speed, cutting depth and feed per cutter tooth were varied. The cutting force, power and densities of heat sources and the temperature in the surface layer of the blank, in the contact zones of the cutter tooth with the blank and the chips with the front surface of the tooth were calculated. It has been found that when milling thin-walled blanks, the temperature field differs significantly from that formed when processing solid blanks due to low heat removal from the unprocessed surface. Increasing the feed per tooth by 45% leads to an insignificant decrease in temperatures in the cutting zone (by 5...12%). Increasing the cutting speed by 25%, on the contrary, leads to an increase in temperatures by 5...10%. Increasing the cutting depth leads to an increase in the temperature in the chip-tooth contact zone by 1.5times and to an increase in the temperature in the tooth-blank contact zone.

Optimization of Motor Rotor Punch Wear Parameters Based on Response Surface Method

To reduce the wear of the motor rotor punching punch and ensure the efficiency is the highest in actual production, the finite element analysis software Deform-3Dv11 is used to simulate the punch wear based on the Archard model theory. With punch wear as the response target and punch speed, punch clearance, and punch edge fillet as the main factors, 17 groups of response surface Box–Behnken test designs are established, as well as a quadratic polynomial regression model between the main factors and the response. The results revealed that: the influence of various parameters on punch wear is in the order of punch edge fillet C > punch clearance B > punch speed A; the order of the interactive influence of various factors is as follows: punch speed and punch edge fillet AC > punch speed and punch clearance AB > punch clearance and punch edge fillet BC. The optimal blanking process combination obtained by using Design-Expert13 software is as follows: blanking speed 50 mm/s, blanking clearance 0.036 mm, and die cutting edge rounded corner 0.076 mm; the predicted response surface value is 6.95 × 10−12 mm. Through simulation verification, the actual optimized simulation value is 6.93 × 10−12 mm, with an absolute relative error of 2.5% for the predicted response value. Moreover, the optimized simulation value is reduced by 30.4% compared to the one before optimization, effectively reducing the punch wear of the motor rotor punching forming and providing a theoretical foundation for further wear optimization.

Progressive Dies for L-hanger Ducting (L-HD) Utilizing Low-Carbon Steel SPCC-SD Material: An Experimental and Numerical Analysis

Industrial developments, especially in the manufacturing and construction sectors, recognize L-hanger ducting as a critical component in HVAC (heating ventilation and air conditioning) ducting systems, which play a role in supporting and stabilizing air ducts. The L-Hanger ducting manufacturing process involves a series of stages, such as shearing, blanking, piercing, trimming, and bending processes. This research focuses on the design and simulation of dies and punches for piercing, blanking, and bending processes using 1.6 mm-thick SPCC-SD material. The aim of this research is to design and analyze progressive dies in order to increase the efficiency of the production process. A comprehensive calculation of the forces involved in the shearing, blanking, piercing, trimming, and bending processes is required in order to predict press machine tonnage requirements to support the production process. This research applies theoretical and numerical validation approaches. Theoretical analysis is used to calculate the overall forces, which are then compared with numerical results and verified through an experimental approach. By understanding and optimizing the design of progressive dies, it is hoped that we can increase the production efficiency of L-hanger Ducting and expand knowledge in the field of metal forming, contributing to the metal forming industry and supporting the development of science.

Microstructure-based modelling of formability for advanced high strength dual-phase steels

The macroscopic formability of advanced high strength dual-phase steels (AHSDPSs) relies highly on the microstructure. Therefore, building the relationship between the microstructure and the formability is vital to enhancing the formability by microstructure optimisation. In this study, a formability model based on microstructure for AHSDPSs was proposed. The tensile simulation of representative volume element (RVE) was implemented to acquire the stress-strain curve (SSC). The forming limit curve (FLC) was constructed based on the method developed in our previous research. The simulation of hole-expansion with the pre-damage of the central-hole induced by the blanking process was conducted to obtain the hole-expansion ratio (HER), in which the vital failure model is developed based on the simulated FLC. For a typical advanced high strength dual-phase steel of DP1180 steel, the prediction errors of SSC, FLC and HER are 5.83 %, 6.85 % and 10.71 %, respectively. The results also depicted that the damage of the prefabricated hole has a noticeable influence on the HER, which could not be ignored for the hole-expansion simulation.

Experimental Analysis and Optimization of Clearance between Punch and Die in Sheet Metal Blanking Process for Soft Steel

Blanking process is commonly used process in production of sheet metal industries to fabricate components. The Global market of sheet metal production is facing highly competition. Due to unavailability of skilled operators and shortage of affordable CAD/CAM systems, it is difficult to predict optimum clearance between punch and die to obtain high quality in small scale industries. Blanking is metal fabricating process and it is characterized by complete material separation. The simulation of the shearing process is complicated as the shear band formed is narrow and fracture criterion is inappropriate. The effect of potential parameters like thickness of sheet, punch-die clearance, tool wear, and punch geometry are studied to investigate their interactions on blanking process. It is important to select process leading parameters which can lead the process such that two similar products from two separate materials can be manufactured on same mold with high quality. This study will help to investigate the effect of thickness of sheet, clearance between punch and die and type of material on blanking process and will help to predict optimal set of parameters to obtain reasonable quality. A mathematical model of blanking process is developed and design of experiments method is used to predict optimum punch-die clearance for soft steel which will result into high quality of component.

Optimization of magnetic circuit in electro-controlled permanent magnet blank holder process with magnetorheological elastomers and analysis of its impact on deep drawing

Addressing the issue of blank holder force (BHF) attenuation caused by the blank-holder gap in the EPMBH process, this study proposes a solution: employing magnetorheological elastomer (MRE) as a magnetic medium to fill these gaps, thus constructing an optimized edging magnetic circuit aimed at reducing magnetic loss and enhancing BHF. Initially, the study utilizes finite element analysis to build a dataset, followed by the application of a particle swarm to optimization BP neural network for magnetic force prediction and modeling. This process reveals the coupling relationship between the working gap thickness, MRE's relative permeability, and magnetic force, where the training and testing results of the model show an average error is around 5 %. Further, by applying a genetic algorithm (GA) to optimize the magnetic permeability of MRE, the theoretical optimal relative permeability curve of MRE is determined. To facilitate production, the goal is set to achieve 98 % of the maximum magnetic force, based on which further optimization is conducted to establish the engineering design range for MRE's relative permeability. Subsequently, MRE samples were designed and manufactured, and combined with a 36-pole EPM magnetic loading mechanism for experimental validation. The results show that the error between the predicted and experimental outcomes is 5.2 %, and the deep drawing experiments further confirm that the introduction of MRE helps the electronically controlled permanent magnet edging process to accommodate the deep drawing needs of slabs with varying thicknesses. This discovery provides valuable guidance for the improvement of the EPMBH process.

Design and Manufacturing of Compound Die

Abstract: The work deals with the development of a combined tool for improvement of a process to be done in piaggio product manufacturing plant. Research work deals with combining two press operations done separately. This operation is done for piaggio battery support bracket, cradle assembly, Bumper cargo. In the first pressing blanking process is done. And in the second operation a hole is pierced in the same product. The objective of research is to develop a tool and process for using a single press for performing dual operation. This is also to reduce downtime, reduce operator fatigue and thereby increase production. Elimination of one operation, one operator and reduction in processing time is also to be achieved.

Energy efficiency improvement of heavy-load hydraulic fine blanking press for sustainable manufacturing assisted by multi-stages pressure source system

The fine blanking process has the highest forming accuracy in the field of metal forming and its production volume has increased sharply. However, hydraulic fine blanking presses (HFBP) – the core equipment of the fine blanking process, have suffered from significant energy loss due to the inefficient hydraulic system. To enhance the energy efficiency of the hydraulic system, this study introduced a novel approach – a multi-stage pressure source system comprised of distinct pump-accumulator groups, each operating at varied supplied pressures to narrow the mismatch of the installed and demanded power. This adaptive system is capable of automatic adjustments to align with the required pressure, thereby mitigating energy losses while concurrently preserving superior dynamic working performance. First, this study commenced with a theoretical analysis of the system configuration and energy characteristics of HFBP. Subsequently, a comprehensive exploration into the inherent inefficiencies of the hydraulic system is undertaken by formulating a precise energy consumption model. Finally, a novel energy-saving optimization design was carried out on the fast-approaching subsystem. The results demonstrated that the implementation of the proposed system led to a notable reduction of 76.87% in energy loss within the flow-regulating module, and an overall diminution of 13.53% in energy dissipation compared to the conventional system. This study will significantly advance sustainable manufacturing practices within the metal-forming domain by reducing electricity consumption and production cost.

Finite element simulation of the complete sheet metal blanking cycle: Effect of blanking clearance on force curve and cut edge quality

Sheet metal blanking process is a manufacturing process that is widely used in sheet metal forming and particularly in the electronics and automotive industries. The outcome and quality of the blanked parts are affected by various parameters such as the blanking clearance, the sheet metal mechanical properties and the wear of tools. However, experimental campaigns to assess the effects of these parameters on the process outcome can be prohibitively expensive for the industry. As a result, numerical simulation of the blanking process is becoming increasingly important to gain insight into the process and study these effects.The present paper provides a novel finite element (FE) simulation procedure to predict the complete blanking cycle including sheet metal cutting, sheet metal springback, punch penetration in die, and stripping phases. A blanking force curve showing the punch force at all phases can thus be obtained. The commercial finite element code ABAQUS® has been chosen to develop this procedure using ABAQUS/Explicit® code for the cutting phase and ABAQUS/Standard® code for the remaining phases. Based on this procedure, the influence of the blanking clearance on the punch force-displacement curve and on the cut edge quality has been studied. The obtained results have been compared to previous literature results and experimental findings.

Accuracy of Modified Johnson–Cook Modelling of the Blanking Process through Experimental and Numerical Analysis

Accuracy of Modified Johnson–Cook Modelling of the Blanking Process through Experimental and Numerical Analysis

A structural-thermal coupled modeling approach on the formation of adiabatic shear bands in steel sheet blanking process

Adiabatic shear banding reflects an unstable and dynamic plastic deformation mechanism occurring at high strain and strain rates which is strongly conjugated to fracture. Current work carries out a numerical study on the initiation and development of adiabatic shear bands (ASBs) in blanking process of AISI 4340 steel sheet. A structural-thermal coupled finite element analysis is developed in LS-DYNA software by implementing a thermo-viscoplastic flow rule for material plasticity and a damage criterion considering dynamic failure. The numerical simulations are focused on capturing ASB genesis through intense shear localization by evincing strain instability. Also, the evolution of ASB mechanism is investigated, aiming to contribute a stage-by-stage propagation and highlight its connection to dynamic failure. Further, the effect of ASB temperature and strain field on fracture is analysed, while the influence of strain/strain rate hardening and thermal softening on strain instability, peak force and the blanked surface is studied. The results revealed an S-shaped ASB due to severe shear localization and significant temperature increase, leading to dynamic recrystallization around punch-die corners and reacting to strain instability and dynamic. Finally, high magnitude thermal softening during ASB development resulted in earlier ASB generation and reduction of the peak blanking force, while further it decreased shear zone expansion and increased fractured length in the blanked surface.

Исследование влияния элементов режима и шага зубьев фрезы на технологические параметры и температурное поле процесса обработки заготовок тонкостенных деталей

When machining workpieces of thin-walled parts, the temperature field differs from the field, which is formed during massive workpieces treatment. The reason for this is that machining of a thin-walled billet is interfered with its surface, being opposite to the one under machining. It has a significant effect on the temperature field, since the intensity of heat removal from this surface into the environment is significantly less than heat removal into the underlying layers of a massive material blank. In this regard, the problem of finding a rational mode of the machining process of thin-walled workpieces is relevant. The aim of the study is to determine the effects of the elements of the milling mode of thin-walled workpieces and milling cutter teeth space on the technological parameters of the milling process of titanium alloy workpieces and to develop recommendations for choosing this milling mode. For this purpose, a numerical modeling of the technological parameters of the milling process of blanks of massive workpieces and thin-walled parts made of titanium alloy, was performed experiencing various combinations of feed to the milling cutter tooth, cutting speed and milling cutter teeth space. When machining a thin-walled workpiece, due to less intense heat removal from the cutting zone into the workpiece, the temperatures in the areas of chip contact with the front surface of the tooth, the back surface of the tooth with the workpiece and the temperature of the workpiece itself are higher than when in a massive workpiece treatment. The patterns of changes in the parameters of the milling process of thin-walled workpieces depending on the feed, cutting speed and the milling cutter teeth space are established. With a larger tool stepover, the average and maximum temperatures in the areas of chip contact with the front surface of the tooth and the back surface of the tooth with the workpiece are lower in most of the combinations of mode elements used. Equations that establish the effect of feed on the milling cutter tooth, cutting speed and spacing of teeth on the parameters of the machining are obtained. The results of the study will allow choosing a rational milling mode and spacing of teeth in the work on workpieces of thin-walled parts made of titanium alloy.

Energy consumption analysis for the fine blanking process

Energy consumption analysis for the fine blanking process

Mathematical modeling and analysis of the tailor rolled blank manufacturing process

A tailor rolled blank (TRB) is a plate of continuously varying thickness with the advantages of lightweight, high strength, and good surface quality. However, it is required that the roll gap can be adjusted online, and the plate and roll produce large elastic deformation in the TRB manufacturing process. These characteristics make the modeling of the force and deformation parameters more difficult. A new mathematical model of roll separating force in the TRB manufacturing process is established taking into account the feature of deformation in this research. The elastic deformation of the strip and the flattening deformation of the roll are considered in order to improve the prediction accuracy of the results. The roll separating forces of the entrance elastic compression region and the exit elastic recovery region are computed using the generalized Hooke's law. A new velocity field is proposed based on the deformation characteristics of the plastic region and velocity boundary conditions, and the power functionals of the internal deformation, shear, friction, and tension are calculated. The analytical models of force and deformation parameters combined the elastic and plastic deformation regions are obtained through iterative operation, which satisfies the convergence condition of the roll separating force and roll flattening. The roll separating force data obtained by the model in this research are compared with the actual measured values in the laboratory, and the deviation value is small, which proves the computational precision of the present model. Additionally, the variations of the entrance velocity and flow volume per second during the TRB manufacturing process are shown, and the influences of the tension and friction factor on the neutral angle and roll separating force are illustrated.

Numerical modeling for shearing of unidirectional carbon fiber reinforced plastic laminates by means of near-net-shape blanking

Structural components made of carbon fiber reinforced plastics (CFRP) exhibit a high degree of lightweight suitability. In order to fulfill geometric and functional requirements, a finishing process step of outer and inner contours is necessary. Near-net-shape blanking processes show potential for economical finishing of CFRP structural components. For the knowledge-based design of a near-net-shape blanking process comparable to fine blanking an understanding of the separation mechanisms during shearing of CFRP laminates is required. Therefore, this paper deals with the development of a finite element (FE) process model for near-net-shape blanking of unidirectional (UD) CFRP laminates with different fiber volume fraction and fiber orientation. Material modeling of the UD CFRP laminates was carried out by means of experimental characterization based on tensile, compression and shear tests. The formulation of the material model was implemented using a VUMAT user subroutine. The application of the blank holder and counter force was realized using a kinematic model based on a VUAMP user subroutine. A validation based on experimental near-net-shape blanking tests will be conducted in the next step.

МОДЕЛЮВАННЯ ТА ОПТИМІЗАЦІЯ ПРОЦЕСУ ЛАЗЕРНОГО РІЗАННЯ МЕДИЧНОГО ЕНДОПРОТЕЗА (СТЕНТА)

When designing technological processes, developers always face tasks aimed at increasing the efficiency of the laser cutting process of tubular blanks, as well as improving technological equipment. The main efforts are aimed at improving the quality indicators, in particular the roughness of the cut surface, as well as the elastic characteristics of medical endoprostheses.The analysis of scientists' research on laser processing of medical endoprostheses made it possible to determine the main priority directions of scientific research, namely the search for ways to improve experimental equipment and optimal control parameters of the technological process of laser processing of tubular thin-walled blanks.The purpose of this is to increase the elastic characteristics of the medical endoprosthesis, in particular its flexibility due to the reduction of the width of the cut, as well as the optimization of the technologicalprocess of laser cutting of the tubular thin-walled blank.On the basis of a priori information, methods and approaches were developed to improve technological equipment in order to increase the productivity and quality of manufacturing medical endoprostheses. Namely, a complex approach was developed to increase the elastic characteristics of the stent by reducing the width of the laser cut. In particular, the methods of mathematical statistics were used for the effective analysis of technological factors affecting the process of laser treatment of medical endopros-theses. Namely, mathematical models of the process of laser cutting of thin-walled tubular blanks were obtained.In this work, the optimal configuration of the experimental prototype of experimental equipment for the manufacture of medical endoprostheses (stents) was developed. Also, a technique was developed and optimization of the control parameters of the process of laser cutting of tubular blanks was carried out. The results of experimental studies showed the possibility of reducing the width of the laser cut, which made it possible to improve the elastic characteristics of the medical endoprosthesis.

Influence of clearance and velocity during blanking on the fatigue behavior of cellulose-based biocomposites

Cellulose-based biocomposites, such as Cottonid, are a promising class of materials to improve the carbon footprint of products during their service life. Cottonid has high technological potential due to its physical and mechanical similarities to engineering plastics and light metals. To replace traditional metallic materials in industry, cellulose-based semi-finished products need to be formed and cut. In particular, blanking is the most cost-effective and industrially common cutting method for metals. However, this study investigates the influence of various blanking process parameters on the quality and the fatigue strength of the resulting cutting edges of Cottonid. The presented results give insights on how the relationships between process parameters during cutting and resulting material properties known from conventional materials can be transferred to cellulose-based biocomposites like Cottonid. The relative clearance was varied between 4 and 10% and the cutting velocity between 0.05 and 10 m/s. It was evident that slower velocities and smaller clearances resulted in visibly better cutting edges. In order to relate this effect to the mechanical performance of Cottonid, new 3-point bend specimens were taken from the blanked strips for fatigue testing. It was found that the fatigue strength was significantly affected by the velocity and clearance. Further, similar to metallic materials, clean-cut (smooth area) and a fractured zone can be clearly distinguished. A good cutting edge quality results in a higher resistance of the Cottonid component against crack initiation at process-induced defects. The knowledge gained may enable an efficient cutting process for cellulose-based materials with higher fatigue strength in the future.

Study on material-data-driven process parameterization in fine blanking

In industrial sheet-metal processing, processes are parameterized based on the material specifications. However, the manufacturing process of sheet-metal coils determines the material properties and as every manufacturing process is subject to variations, variations in material properties occur in the semi-finished product influencing the subsequent sheet-metal processing. The production of high-quality parts requires considering these varying material properties to adapt the processes accordingly. This paper shows that material data from non-destructive eddy current measurements and process data of the coil production enable decision support for the parameterization of fine blanking processes. A material-data-driven approach using material data recorded in an industrial setting is employed to investigate the influence of parameter settings in the fine blanking process on specific quality characteristics of fine blanked workpieces.