A Review of Fine Blanking: Influence of Die Design and Process Parameters on Edge Quality
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JMEPEG https://doi.org/10.1007/s11665-020-05339-y
A Review of Fine Blanking: Influence of Die Design and Process Parameters on Edge Quality U. Aravind
, Uday Chakkingal, and P. Venugopal
Submitted: 25 August 2020 / Revised: 22 October 2020 / Accepted: 1 November 2020 Conventional blanking is the single-stroke shearing of closed contour profiles. However, the blanked pieces have inherent errors like fractured cut surface and blank dishing necessitating further sizing and/or finishing operations. Fine blanking is a more precise version of the blanking operation with lesser errors such that post-forming steps required will be minimal. Thus, it is an ideal candidate for manufacturing precision machine components. This review paper starts with the introduction to the process. Then, studies aimed at the analysis of fine blanking tooling and process parameters and their effect on fine-blanked part characteristics are presented. Inferences from studies on the design of equipment for fine blanking, deformation mechanics involved and the fine blanking performance of different materials are also discussed. The use of finite element simulation studies to understand the process better has also been determined. Various reported strain measurement techniques are then discussed. The recent improvement in techniques like in situ digital image correlation enables accurate experimental measurement of strain in the shear zone which can be used to validate the findings from FE simulations. Fine blanking process modifications that aimed at cost reduction or improvement in product quality are summarized as well. Keywords
blanking, fine blanking, fine piercing, metal cutting, precision blanking, punching
1. Introduction 1.1 Conventional Blanking Process Blanking (DIN 8580) is defined as a metal shearing process with a completely enclosed cutting line (Ref 1). An example of conventional metal punching/blanking done on a circular brass sheet is shown in Fig. 1. When the cutout piece is meant to be the functional part, the process is called blanking. On the other hand, if the pierced blank is meant to be the useful part, then it is known as punching or piercing (Ref 2). For example, a washer or a ratchet gear can be made by a combination of punching and blanking operations in a single stroke. The process can thus be used to produce more complex profiles of cut as well, finding a wide range of applications in the sheet metal forming industry. A schematic of the conventional blanking process is shown in Fig. 2. The primary components of the tooling are a sharpedged punch and a sharp-edged die, with the cross section the same as the desired profile of cut. A clearance of about 10% of the thickness of the material is usually provided between the punch and the die per side as per standard (Lange 1985). In the case of punching, the clearance is given by increasing the dimension of the die, keeping the dimension of the punch cross section to be the same as that of the desired hole. In the case of blanking, the dimension of the die would be the same as that o
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