Blanking and Fineblanking

Simulation Techniques in Manufacturing Technology

Lecture 5
Laboratory for Machine Tools and Production Engineering
Chair of Manufacturing Technology

Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. F. Klocke

WZL/Fraunhofer IPT

Outline
1

Introduction

Requirements on blanking parts

Shearing

Fineblanking

Calculation of blanking parts

WZL/Fraunhofer IPT

Seite 2

Introduction

Sheet Metal Forming Processes

Manufacturing Processes

according to DIN 8580ff

Casting

Compressive
Forming
Open Die
Forging
Closed Die
Forging
Cold Extrusion
Rod Extrusion
Rolling
Upsetting
Hobbing
Thread Rolling

WZL/Fraunhofer IPT

Forming

TensoCompressive
Forming
Deep Drawing
Ironing
Spinning
Hydroforming
Wire Drawing
Pipe Drawing
Collar Forming

Cutting

Tensile
Forming
Stretch Forming
Extending
Expanding
Embossing

Joining

Bend Forming
With linear
Tool
Movement
With
rotating Tool
Movement

Coating

Shear
Forming
Translate
Twist
Intersperse

Changing of
Material Properties

Severing
Shearing
Fine Blanking
Cutting with a
single Blade
Cutting with
two approaching
Blades
Splitting
Tearing

Seite 3

Introduction

What is blanking?

Definition:
Mechanical separation of workpieces by a shearing process without formation of chips
if necessary, including additional forming-operations.
WZL/Fraunhofer IPT

Seite 4

Outline
1

Introduction

Requirements on blanking parts

Shearing

Fineblanking

Calculation of blanking parts

WZL/Fraunhofer IPT

Seite 5

Requirements on blanking parts

Required quality of blanking parts

surface evenness
angular deviation

draw-in
achievable
roughness
rupture zone
smooth sheared zone
cutting burr

WZL/Fraunhofer IPT

Seite 6

Outline
1

Introduction

Requirements on blanking parts

Shearing

Fineblanking

Calculation of blanking parts

WZL/Fraunhofer IPT

Seite 7

Shearing - Introduction

Shearing Introduction
application

IT-classification

costs

output

fine (IT 7)

high

low

rough (IT 11)

low

high

sheared
surface

Shearing

WZL/Fraunhofer IPT

Seite 8

Shearing - Characterisation of the process

Open and closed cut in shearing

open cut

tool flank

WZL/Fraunhofer IPT

closed cut

open flank
Seite 9

Shearing - Characterisation of the process

Differentiation of blanking and piercing

blanking

piercing

waste

waste
WZL/Fraunhofer IPT

Seite 10

Shearing - Characterisation of the process

Tool design of shearing

punch

u die clearence
app. 0,05 x sheet thickness
with:
u = (a a1)

blank holder
U

a dimension of cutting die

a1 punch dimension

sheet metal

relief angle
of cutting die
blanking die

WZL/Fraunhofer IPT

Seite 11

Shearing - Characterisation of the process

Process sequences of shearing

charging of
the punch

elastic
& plastic
deformation

shearing
& cracking

break through

WZL/Fraunhofer IPT

Seite 12

Shearing Achievable accuracy

Errors on sheared workpieces

draw-in
draw-in height hE
hE

shearing zone

rupture zone
hG

burr height hG

tR

crack depth tR
WZL/Fraunhofer IPT

Seite 13

Shearing Achievable accuracy

Influence of die clearance on the sheared surfaces

formation of distortion wedge
small
clearance

no formation of distortion wedge

big
clearance

By a small die clearance, distortion wedges are generated by squeezing of the material
between two cracks
WZL/Fraunhofer IPT

Seite 14

Shearing Achievable accuracy

specific die clearance:

die clearance uS / sheet thickness s

Quality of sheared surface depending on specific die clearance

WZL/Fraunhofer IPT

Seite 15

Shearing Achievable accuracy

Influence of specific die clearance on crack depth

Crack depth
tR
sheet thickness s

blanking

Part diameter
da = 30 mm

specific die clearance us / %

WZL/Fraunhofer IPT

Seite 16

Shearing Achievable accuracy

Relation between burr height and number of cuts

ductile
sheet

brittle
sheet

burr height
WZL/Fraunhofer IPT

Seite 17

Shearing - Forces in shearing

Reduction of cutting force by modification of tools

sloped
cut

plane
cut

h = 0 (plane cut)

Fmax
0,9 Fmax
force F

h = 1/3 s (sloped cut)

work s(h=0) = work s(h=2s)

=

0,6 Fmax

h = s (sloped cut)

h = 2s
(sloped cut)
0,3 Fmax

Contact between punch and sheet

2s

3s

total punch stroke

Due to workpiece-bending, sloped cut is only suited for piercing.

WZL/Fraunhofer IPT

Seite 18

Shearing - Forces in shearing

Reduction of cutting force by modification of tools

plane cut

conical die

WZL/Fraunhofer IPT

sloped cut

grooved die

grooved punch

conical punch

punch offset

Seite 19

Shearing - Forces in shearing

Dependence of quality on shearing strength of carbon steel

carbon concentration

tensile strength

breaking elongation

sheet thickness

die clearance

part diameter

aspect ratio

Die / punch radius

Cutting resistance kS is defined as the cutting force (Fs) referring to the cutting surface
kS = FSmax / AS
(with As= ls*s)
WZL/Fraunhofer IPT

Seite 20

Shearing Wear

Wear on the punch

fatigue wear and wear on front
face especially appear for lower
sheet thickness (s < 2 mm)

fatigue wear on front face

wear on front face

wear on shaft area

is caused by friction between
punch and sheet in direction of
punch movement
appears during cutting of thicker
sheets (s 2 mm)
wear on shaft area
WZL/Fraunhofer IPT

Seite 21

Shearing wear

Influences on wear
Tool

Machine
material
hardness
surface
guidance
die clearance

stiffness
kinematics

tool wear
Workpiece
Type of process
open cut

alloy
stiffness
hardness
dimension
shape

closed cut

open cut
closed cut

Source: reiner, Mller Weingarten, Feintool

WZL/Fraunhofer IPT

Seite 22

Shearing Tool design

Multi-stage blanking tool

4 stage
Multi-stage blanking tool
for shearing of rotor- and
stator-sheets

stator

WZL/Fraunhofer IPT

rotor

Seite 23

Outline
1

Introduction

Requirements on blanking parts

Shearing

Fineblanking

Calculation of blanking parts

WZL/Fraunhofer IPT

Seite 24

Fineblanking - Introduction

Fineblanking - Introduction
application

IT-classification

costs

output

fine (IT 7)

high

low

rough (IT 11)

low

high

sheared
surface

fineblanking

shearing

WZL/Fraunhofer IPT

Seite 25

Fineblanking Characterisation of the process

Animation of fineblanking
clamping

plastic deformation

cutting

WZL/Fraunhofer IPT

Seite 26

Fineblanking Characterisation of the process

Differences between shearing and fineblanking

shearing

fineblanking

FS punch force

FS punch force
FR vee ring and blank
holder force
FG counter punch
force

1 cutting die
(2 guiding plate)
3 punch

1 cutting die
2 vee ring and
blank holder
3 punch
4 counter punch
5%

WZL/Fraunhofer IPT

die clearance

0,5%
Seite 27

Fineblanking Details

Geometry of vee rings

vee ring

thin sheets

cutting line

sheet thickness s
3 5 mm

outward notch

toothed
inward notch

cutting die

thick sheets
blank holder
with vee ring

sheet thickness s
5 15 mm
vee ring

intention:

WZL/Fraunhofer IPT

cutting line

create compression stresses

prevent horizontal movement of the
sheet / material flow
Seite 28

Fineblanking - Details

Dependence of workpiece quality on influencing quantities

Process parameters affect workpiece quality:
example:
counter punch force

draw-in width

draw-in height

smooth shearing
zone

deflexion

Workpiece quality can be influenced by process parameters:

example:
draw-in height

WZL/Fraunhofer IPT

die clearance

sheet thickness

blank holder force

counter punch
force
Seite 29

Fineblanking obtainable precision

Definition of degree of difficulty in fineblanking

degree of difficulty

slot a, stick b / mm

edge radius ri , ra / mm

edge angle a

S1 easy
S2 medium
S3 difficult

sheet thickness s / mm
WZL/Fraunhofer IPT

sheet thickness s / mm
Seite 30

Fineblanking comparison of techniques

Comparison of sheared surface in shearing and fineblanking

shearing

fineblanking

In fineblanking, the smooth sheared zone can take a share of 100%

WZL/Fraunhofer IPT

Seite 31

Fineblanking application

Application examples

fineblanking

shearing

In fineblanking, the sheared surface can be used as a functional surface

WZL/Fraunhofer IPT

Seite 32

Fineblanking Field of application

Application examples in automotive industry

gear shifting gate

door lock

window lift

synchronising disc

valve plate

belt pretensioner

gear

ABSpulse generator
brakes

seat adjustment
WZL/Fraunhofer IPT

seat belt components

cooling system
Seite 33

Outline
1

Introduction

Requirements on blanking parts

Shearing

Fineblanking

Calculation of blanking parts

WZL/Fraunhofer IPT

Seite 34

Calculation of blanking process

Analytical calculation method

Principals and drawbacks

FEA of (fine)blanking processes

Advantage over analytical calculation by means of examples

WZL/Fraunhofer IPT

Seite 35

Calculation of blanking process - cutting force

FS max = s l S k S

maximum cutting force

s :sheet thickness
lS :length of cutting line
kS :cutting resistance

k S = 0,8 R m

WZL/Fraunhofer IPT

approximate calculation with

tensile strength

Seite 36

Calculation of blanking process - cutting energy

xg

WS =

F (x )dx
S

cutting energy

x :cutting distance
FS :current cutting force

W S = c x g FS max

WZL/Fraunhofer IPT

c :correction factor
including variables like
material properties,
effective cutting distance,
size of die clearance and
friction

Seite 37

Calculation of fine blanking process - vee ring force

FR = 4 l R hR R m

approximation value for the vee ring force

lR :length of vee ring

hR :overall height of vee ring
Rm :material tensile strength

WZL/Fraunhofer IPT

Seite 38

Calculation of fine blanking process - counter punch force

FG = Aq q G

Approximation for the counter punch force

Aq :cutting piece surface
qG :specific counter punch force

WZL/Fraunhofer IPT

N
q G = 20
mm 2

Value of the specific counter punch force for

small sized, thin workpieces

N
q G = 70
mm 2

Value of the specific counter punch force for

large, thick workpieces

Seite 39

Calculation of fine blanking process - cutting force

FS = FSt FG
FS max
FS max
kS =
=
AS
lS s
k
C1 = S
Rm
FS = l g s S = C1 l g s R m

cutting force
FSt :punch force
FG :counter punch force
shearing resistance
Fsmax :maximum cutting force
AS :shearing surface
factor of shearing strength
kS :shearing resistance
Rm :tensile strength
calculation according to VDI-standard 3345
lg
s
S
C1

:total length of cutting lines

:material thickness
:shear strength
:factor of shearing strength due to
yield stress ratio
Rm :material tensile stress

0 , 6 < C 1 < 0 ,9
WZL/Fraunhofer IPT

advised value is C1= 0,9 (safety)

Seite 40

Simulation fine blanking

Simulation of fine blanking offers the opportunity to include:
flow stress data
friction properties
thermomechanical coupling
More exact input data can be enclosed:

instead of

FS = C1 l g s R m

R m = const .
This leads to the following results:
force over punch travel
stress field
strain rate field
draw-ins
prediction of fracture
WZL/Fraunhofer IPT

Seite 41