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

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Outline
1 Introduction

2 Requirements on blanking parts

3 Shearing

4 Fineblanking

5 Calculation of blanking parts

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Introduction
Sheet Metal Forming Processes

Manufacturing Processes
according to DIN 8580ff

Changing of
Casting Forming Cutting Joining Coating Material Properties

Tenso-
Compressive Tensile Shear
Compressive Bend Forming Severing
Forming Forming Forming Forming

Open Die Deep Drawing Stretch Forming With linear Translate Shearing
Forging Ironing Extending Tool Twist Fine Blanking
Closed Die Spinning Expanding Movement Intersperse Cutting with a
Forging Hydroforming Embossing With single Blade
Cold Extrusion Wire Drawing rotating Tool Cutting with
Rod Extrusion Pipe Drawing Movement two approaching
Rolling Collar Forming Blades
Upsetting Splitting
Hobbing Tearing
Thread Rolling

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Introduction
What is blanking?

Definition:
Mechanical separation of workpieces by a shearing process without formation of chips –
if necessary, including additional forming-operations.
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Outline
1 Introduction

2 Requirements on blanking parts

3 Shearing

4 Fineblanking

5 Calculation of blanking parts

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Requirements on blanking parts
Required quality of blanking parts

surface evenness

angular deviation

draw-in

achievable
roughness
rupture zone
smooth sheared zone
cutting burr

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Outline
1 Introduction

2 Requirements on blanking parts

3 Shearing

4 Fineblanking

5 Calculation of blanking parts

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Shearing - Introduction
Shearing – Introduction
application IT-classification costs output sheared
surface
fine (IT 7) high low

Shearing

rough (IT 11) low high

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Shearing - Characterisation of the process
Open and closed cut in shearing

open cut closed cut

tool flank open flank

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Shearing - Characterisation of the process
Differentiation of blanking and piercing

blanking piercing

waste

waste

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Shearing - Characterisation of the process
Tool design of shearing

u – die clearence punch

app. 0,05 x sheet thickness
with:
u = ½ · (a – a1)
blank holder
U
a – dimension of cutting die

a1 – punch dimension sheet metal

α – relief angle
of cutting die
blanking die

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Shearing - Characterisation of the process
Process sequences of shearing
charging of 1 2 elastic
the punch & plastic
deformation

shearing 3 4 break through

& cracking

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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

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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
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Shearing – Achievable accuracy
Quality of sheared surface depending on specific die clearance

die clearance uS / sheet thickness s

specific die clearance:

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Shearing – Achievable accuracy
Influence of specific die clearance on crack depth

blanking

Part diameter
da = 30 mm

tR
sheet thickness s
Crack depth

specific die clearance us / %

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Shearing – Achievable accuracy
Relation between burr height and number of cuts

ductile
sheet

brittle
sheet

burr height

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Shearing - Forces in shearing
Reduction of cutting force by modification of tools
plane sloped Fmax h = 0 (plane cut)
cut cut
0,9 Fmax
h = 1/3 s (sloped cut)

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

s h 0,6 Fmax h = s (sloped cut)

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

Contact between punch and sheet

0 s 2s 3s
total punch stroke
Due to workpiece-bending, sloped cut is only suited for piercing.
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Shearing - Forces in shearing
Reduction of cutting force by modification of tools
plane cut sloped cut grooved punch conical punch

conical die grooved die

punch offset

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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)

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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

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Shearing – wear
Influences on wear
Tool Machine
material
hardness
surface
guidance stiffness
die clearance kinematics

tool wear

Workpiece
Type of process
open cut closed cut
alloy open cut
stiffness closed cut
hardness
dimension
shape

Source: reiner, Müller Weingarten, Feintool

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Shearing – Tool design
Multi-stage blanking tool

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

stator rotor

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Outline
1 Introduction

2 Requirements on blanking parts

3 Shearing

4 Fineblanking

5 Calculation of blanking parts

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Fineblanking - Introduction
Fineblanking - Introduction
application IT-classification costs output sheared
surface
fine (IT 7) high low

fineblanking

shearing

rough (IT 11) low high

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Fineblanking – Characterisation of the process
Animation of fineblanking
clamping

plastic deformation

cutting

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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 1 – cutting die

(2 – guiding plate) 2 – vee ring and
3 – punch blank holder
3 – punch
4 – counter punch

5% die clearance 0,5%

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 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 cutting line

intention:
• create compression stresses
• prevent horizontal movement of the
sheet / material flow

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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
deflexion
zone

Workpiece quality can be influenced by process parameters:

example:

draw-in height die clearance sheet thickness

counter punch
blank holder force
force

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Fineblanking – obtainable precision
Definition of degree of difficulty in fineblanking
degree of difficulty
S1 – easy
S2 – medium
edge angle a
S3 – difficult

edge radius ri , ra / mm
slot a, stick b / mm

sheet thickness s / mm sheet thickness s / mm

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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%

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Fineblanking – application
Application examples

fineblanking

shearing

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

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Fineblanking – Field of application
Application examples in automotive industry
gear shifting gate door lock window lift

synchronising disc
valve plate

gear belt pretensioner

ABS-
pulse generator
brakes

seat adjustment seat belt components cooling system

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Outline
1 Introduction

2 Requirements on blanking parts

3 Shearing

4 Fineblanking

5 Calculation of blanking parts

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Calculation of blanking process

• Analytical calculation method

Principals and drawbacks

• FEA of (fine)blanking processes

Advantage over analytical calculation by means of examples

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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 approximate calculation with

tensile strength

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Calculation of blanking process - cutting energy
xg

WS = ∫ F (x )dx
0
S cutting energy

x :cutting distance
FS :current cutting force

W S = c ⋅ x g ⋅ FS max c :correction factor

including variables like
material properties,
effective cutting distance,
size of die clearance and
friction

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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

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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

N
q G = 20 Value of the specific counter punch force for
mm 2 small sized, thin workpieces

N
q G = 70 Value of the specific counter punch force for
mm 2 large, thick workpieces

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Calculation of fine blanking process - cutting force
FS = FSt − FG cutting force
FSt :punch force
FG :counter punch force
FS max FS max
kS = = shearing resistance
AS lS ⋅ s Fsmax :maximum cutting force
AS :shearing surface
k
C1 = S factor of shearing strength
Rm kS :shearing resistance
Rm :tensile strength
FS = l g ⋅ s ⋅ τ S = C1 ⋅ l g ⋅ s ⋅ R m calculation according to VDI-standard 3345
lg :total length of cutting lines
s :material thickness
τS :shear strength
C1 :factor of shearing strength due to
yield stress ratio
Rm :material tensile stress
0 , 6 < C 1 < 0 ,9 advised value is C1= 0,9 (safety)

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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

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