STATISTIC PROCESSING OF THE EXPERIMENTAL DATA OBTAINED

AFTER BAR STRIP SHEET COOL HARDENING DURING

TECHNOLOGICAL AND BLANKING OPERATIONS

Alin STĂNCIOIU*
Gheorghe GÎRNICEANU**
Gheorghe POPESCU***
* Lect. dr. eng. U.C.B, Tg-Jiu, e-mail alin@utgjiu.ro
** Prof. dr. eng. U.C.B,Tg-Jiu, e-mail girniceanu@utgjiu.ro
*** Prof. dr. eng. U.C.B,Tg-Jiu, e-mail gepo@utgjiu.ro

Keywords: tensions, deformations, hardness, statistic.

Abstract: By statistically processing the experimental research results, mathematic patterns have been
obtained with cool hardening dependences in comparison with the active tools penetration into the sheet
material, through which tension and deformations states can be appreciated. Besides the mathematic
expression there was also obtained a graphic representation of the hardness increase dependence in report
with the independent variable. The mathematic modeling allowed also to obtain some results and displays a
concluding image upon the phenomenon’s evolution way.

1.Introduction.
The hardness analysis method is based on the fact that, in cold plastic deformation,
the metallic shape modification is accompanied by some modifications of the physical-
mechanic properties, mainly the material hardness, especially when being deformed the
material is more powerfully cool hardened.
On the basis of the dependences between hardness and deformations intensity or
between hardness and tensions intensity, generally expressed under the form of graphics
drawn as a results of some tests series made for some materials, the tensions and
deformations states that appear in a deformed body through a certain procedure may be
immediately appreciated, by measuring the hardness from the places that interest us in the
respective body. For example, figure 1 displays the hardness graphics regarding the
deformations intensity and the tensions intensity for proof samples from steel similar to
OLC 20.

Fig. 1 Hardness variation graphic regarding tensions intensity and deformations intensity

The method of deformation degree and tension state analysis by analyzing the
hardness of the deformed material is simple, but rather approximate.

2. The influence of the tool wear on cool hardening of the bar strip material
Tool wear may be directly monitored through the cool hardening effect upon the
processed bar strip. For this purpose, it has been determined the Vickers hardness 0,5daN
of the pressed material with cool hardening effect from the force plug and the matrix. The
hardness measurement has been done as in figure 2.

Fig.2 force plug, 2 and 5 – the places where hardness was measured, 3 – bar strip, 4- matrix.

On the basis of the dependences between hardness and active tool penetration into
the bar strip sheet, expressed by algebraic relations and graphics compared to
experimental results, we can appreciate the tensions and deformation states, by
measuring the hardness in the material cool hardened areas.
In table nr.1 we display the values of the Vickers hardness 0,5daN of the strip bars
deformed by force plugs obtained in the research.

Table nr.1 with HV 0,5 in daN/mm2 hardness made by force plugs on bar strips
Nr. Covered Chromate Improved Nitride
Penetration Improved
crt. sparks OSC10 OSC10 205Cr115 OSC10
[0,01 OSC10 die
die die die die
mm] [HV]
[HV] [HV] [HV] [HV]
1. 33 117 123 129 134 164
2. 66 138 140 143 147 187
3. 99 145 146 152 157 193
4. 132 156 162 170 178 200
5. 165 168 169 179 181 210
6. 198 174 180 189 197 225
7. 231 180 188 195 210 241
8. 240 260

3. Statistic processing of experimental data

By statistically processing the experimental research results, mathematic patterns
have been obtained with cool hardening dependences in comparison with the active tools
penetration into the sheet material. Besides the mathematic expression there was also
obtained a graphic representation of the hardness increase dependence in report with the
independent variable.
The mathematic modeling allowed also to obtain some results and displays a
concluding image upon the phenomenon’s evolution way. The dependence between y
hardness and x penetration for force plugs is displayed in the algebraic expressions from
table nr.2, and the graphic response in the figures 3-7 for the polynomial mathematic
patterns.
The mathematic patterns graphics are represented by red continuous curves, and
the experimental graphics values are represented by blue discontinuous lines.

Table nr.2 Algebraic expressions

y = 26+4.77475*x-0.08035*x^2+6.62038e-4*x^3-
2.52968e-6*x^4+3.61991e-9*x^5+eps
Covered sparks OSC10 die y = 116.227*exp( 0.002*x)+eps
y = 1.946+74.266*log10(x)+eps
 y = 68.28571+2.79431*x-0.0453*x^2+2.88647e-4*x^3-
1.46926e-6*x^4+2.12936e-9*x^5+eps
Chromate OSC10 die y = 119.149*exp( 0.002*x)+eps
y = 2.556+76.061*log10(x)+eps
y = 92.286+1.87406*x-0.03126*x^2+2.88647e-4*x^3-
1.19776e-6*x^4+1.80996e-9*x^5+eps
Improved 205Cr115 die y = 123.675*exp( 0.002*x)+eps
y = -0.374+80.911*log10(x)+eps
y = 138-0.52681*x+0.01599*x^2-1.17841e-4*x^3+
3.76897e-7*x^4-4.25872e-10*x^5+eps
Nitride OSC10 die y = 126.461*exp( 0.002*x)+eps
y = -8.499+88.159*log10(x)+eps
y = 49.26744+6.04555*x-0.10203*x^2+8.27814e-4*x^3-
3.1513e-6*x^4+4.57966e-9*x^5+eps
Improved OSC10 die y = 157.842*exp( 0.002*x)+eps
y = 10.625+95.439*log10(x)+eps

By accomplishing the graphic processing of the experimental research results we

may observe the evolution of the bar strip material hardness increase and the eventual
optimum technologies of active tools accomplishment for which the hardness value is
minimum. With the help of these mathematic patterns we may obtain a clear image of the
independent variable influence upon the response value (cool hardening).

Polynomial mathematic patterns graphics for approximating the force plugs

hardness evolution
190 200

180 190

170 180
Duritatea [HV]

170
Duritatea [HV]

160
160
150
150
140
140
130 130

120 120

110 110
33 66 99 132 165 198 231 240 33 66 99 132 165 198 231 240

Penetration [0,01mm]
Patrunderea [0,01mm] Penetration [0,01mm]
Patrunderea [0,01mm]

Fig.3 Covered sparks OSC10 die Fig.4 Chromate OSC10 die

200
220
190

180 200
Duritatea [0,01mm]

170
Duritatea [HV]

180
160

150 160

140
140
130

120 120
33 66 99 132 165 198 231 240 33 66 99 132 165 198 231 240

Penetration
Patrunderea[0,01mm]
[0,01mm] Penetration
Patrunderea[0,01mm]
[0,01mm]

Fig.5 Improved 205Cr115 die Fig.6 Nitride OSC10 die

 270

250

230

Duritatea [HV]
210

190

170

150
33 66 99 132 165 198 231 240

Penetration [0,01mm]
Patrunderea [0,01mm]

Fig.7 Improved OSC10 die

4. Conclusions
From the values obtained after the multiple regression analysis we observe that the
mathematic patterns are adequate because the main established parameters are framed
within the admissible values field.
Because the matrixes and force plugs edges are rounded due to wear, they have
deformed the bar strip sheet causing cool hardening.
Every force plug has differently hardened the material, penetration function, due to
the different edge wear of the active tools.
- We observe that the greatest value of the cool hardened material is when cutting
with the OSC 10 improved force plug, and the least value with the OSC 10 force
plug covered with sparks.
- The same behaviour is registered also for the deformations caused by the matrixes
that worked together with the respective force plugs;
- The cool hardening caused by the matrixes effect is superior to that caused by the
force plugs effect;
- The cool hardening maximum value caused by the chromed OSC 10 force plug is
bigger than the one of the OSC 10 force plug covered with sparks, therefore having
a lower hardness, but its behaviour in the cutting process is satisfactory;
- The nitrated OSC 10 force plugs and 295Cr115 improved force plug have durability
between those mentioned before and the improved OSC 10 force plug.

BIBLIOGRAPHY:

[1] Stăncioiu Alin, Cercetări cu privire la influenţa calităţii sculelor asupra proceselor tehnologice de
tăiere, Universitatea din Craiova, Teza de Doctorat, 2004
[2] Şontea, Sever., Tratamente termice şi termochimice , Editura Spirit Românesc, Craiova, 2001
[3] Şontea, Sever, Calitatea acoperirilor prin cromare dură , Revista Tratamente termice, Nr.5. 1993
 THE COMPARATIVE ANALYSIS OF THE BLANKING TOOL WEAR USING THE
OPTICAL METHOD BY COMPARING THE RIDGE MEASURE

Alin STĂNCIOIU*
Gheorghe GÎRNICEANU**
Gheorghe POPESCU***
* Lect. dr. eng. U.C.B, Tg-Jiu, e-mail alin@utgjiu.ro
** Prof. dr. eng. U.C.B,Tg-Jiu, e-mail girniceanu@utgjiu.ro
*** Prof. dr. eng. U.C.B,Tg-Jiu, e-mail gepo@utgjiu.ro

Keywords: cutting, lubricant, shiny, surface

Abstract: In the case of the tools for metallic materials cold trim, as a duration measure for assuring the
adequate development of the technological process both the force plug or the matrix dimensional
modifications measure are taken, but also the ridge height (the degree) which is determined by the tool wear
degree.When the degree (ridge) overcomes a certain value (prescribed through the quality requirements of
the processed pieces) the continuing use of the tool (therefore increasing its use duration) there is no longer
admitted even if the technologic process may continue. The experiment proved that the ridge measure is
directly proportional with the active elements wear.

1.Introduction.
The ridge cutting is executed both by obtaining finite pieces, and through bar strips
for later operations of deformation processing.
Blanking contains several procedures like: fret sawing, boring, corrugation, clipping,
graduation, etc.

Fig. 1 The cold cutting process
diagram of a metallic material
Fig. 2 Areas that appear in a Fig. 3 Micro and macrocracks
cutting and bar stripping section development mechanism
into the cutting and bar
stripping process:
δ, blanking thickness.

The mechanism of the cutting and boring process is schematically presented in

figure 1 it includes 3 characteristic phases:
- the request of the elastic state material (figure 4), when combined efforts do not
overcome the processed material flow limit: the cutting edges go into the material
causing a slight sheet curving within the limit of j slack between the two cutting
edges I and II. Zone 1 (fig. 2) that corresponds to this phase, has a shiny aspect,
without flowing lines.
- the request of the plastic state material (figure 5), while combining efforts due to the
cutting edge pressing, they overcome the processed material flow limit, that flows
towards the direction of the mobile cutting element hauling direction (the knife or the
scissors disk, perforating force plug). The zone aspect (2, fig. 2) is even, due to
specific plastic flow.
- The breaking phase (fig. 6) corresponding to the central portion which, by reducing
itself while the cut edge enters the material, cannot take over the efforts caused by cutting
edges pressing and it breaks. The surface aspect in this area (3, figure 2) is uneven,
specific to breaking.

Fig.4. The request of the elastic state material Fig.5 The request of the plastic state material

Fig.6 The breaking phase Fig.7 Piece

The material separation begins when the unitary efforts transmitted through the two
cutting edges I and II (figure 1) creates plastic deformation areas on the material (section)
thickness, which coalesces. When plastic flow is no longer possible in this area,
microcracks and macrocracks begin to appear, and they propagate into the material on its
thickness, favouring the breaking of the remained h section, (figure 3).
The thickness (height) in the area where macrocracks began to appear, the h zone,
is the uneven aspect zone (zone 3 in figure 2) and represents “the ridge” or “the degree”,
characterizes through its height, evenness and the quality of the finished product surface,
obtained by processing; the bigger this zone is, the least the evenness of the processed
surface is and the lower the product quality.

2. Comparison using the optical method between the disk plate obtained through
dry blanking with lubricant.
Next, they investigated the weight of the disk plates ridges obtained by blanking
with all the force plugs used in experiments: improved 205Cr115 die, chromate OSC10
die, covered sparks OSC10 die, nitride OSC10 die, improved OSC10 die, improved
OSC10 unworn die.
 In the figures 8-13 there are displayed the images of the cutting sections in two
cases: with dry friction (above) and with lubricated friction (the bottom part) with the
increase degree 5X.

The elastic and plastic deformations area.

Fig.8 Improved 205Cr115 die 5X

The breaking area

Fig.9 Chromate OSC10 die 5x

Fig.10 Covered sparks OSC10 die 5x

Fig.11 Nitride OSC10 die 5X

 Fig.12 Improved OSC10 die 5x

Fig.13 Improved OSC10 unworn die 5x

3. Conclusions:
In the resulted section after cutting, we can observe an even, shiny area, specific to
plastic deformation and an uneven area, typically for breaking.
The smallest ridges are met at the blanked disk plates with OSC10 force plug
covered with sparks and chrome.
The ridges of the disk plates blanked under dry friction conditions are more visible
than those of the disk plates obtained under conditions of dry friction. In conclusion, the
OSC10 force plug covered by sparks has had the least wear.

BIBLIOGRAPHY:

[1] Stăncioiu Alin, Cercetări cu privire la influenţa calităţii sculelor asupra proceselor tehnologice de
tăiere, Universitatea din Craiova, Teza de Doctorat, 2004
[2] Şontea, Sever., Tratamente termice şi termochimice , Editura Spirit Românesc, Craiova, 2001
[3] Şontea, Sever, Calitatea acoperirilor prin cromare dură , Revista Tratamente termice, Nr.5. 1993
 STATISTIC PROCESSING OF THE EXPERIMENTAL DATA OBTAINED
AFTER BAR STRIP SHEET COOL HARDENING DURING
TECHNOLOGICAL AND BLANKING OPERATIONS

Alin STĂNCIOIU*
Gheorghe GÎRNICEANU**
Gheorghe POPESCU***
* Lect. dr. eng. U.C.B, Tg-Jiu, e-mail alin@utgjiu.ro
** Prof. dr. eng. U.C.B,Tg-Jiu, e-mail girniceanu@utgjiu.ro
*** Prof. dr. eng. U.C.B,Tg-Jiu, e-mail gepo@utgjiu.ro

Keywords: tensions, deformations, hardness, statistic.

Abstract: By statistically processing the experimental research results, mathematic patterns have been
obtained with cool hardening dependences in comparison with the active tools penetration into the sheet
material, through which tension and deformations states can be appreciated. Besides the mathematic
expression there was also obtained a graphic representation of the hardness increase dependence in report
with the independent variable. The mathematic modeling allowed also to obtain some results and displays a
concluding image upon the phenomenon’s evolution way.
The mathematic modeling allowed also to obtain some results and displays a concluding image upon
the phenomenon’s evolution way. The dependence between y hardness and x penetration for force plugs is
displayed in the algebraic expression.

Table nr.1
y = 68.28571+2.79431*x-0.0453*x^2+2.88647e-4*x^3-
1.46926e-6*x^4+2.12936e-9*x^5+eps
Chromate OSC10 die y = 119.149*exp( 0.002*x)+eps
y = 2.556+76.061*log10(x)+eps

The graphic response is displayed in in the figures for the polynomial mathematic patterns.
190 200

180 190

170 180
Duritatea [HV]

170
Duritatea [HV]

160
160
150
150
140
140
130
130

120 120

110 110
33 66 99 132 165 198 231 240 33 66 99 132 165 198 231 240

Penetration [0,01mm]
Patrunderea [0,01mm] Penetration [0,01mm]
Patrunderea [0,01mm]

Fig.1 Covered sparks OSC10 die Fig.2 Chromate OSC10 die

BIBLIOGRAPHY:

[1] Stăncioiu Alin, Cercetări cu privire la influenţa calităţii sculelor asupra proceselor tehnologice de
tăiere, Universitatea din Craiova, Teza de Doctorat, 2004
[2] Şontea, Sever., Tratamente termice şi termochimice , Editura Spirit Românesc, Craiova, 2001
[3] Şontea, Sever, Calitatea acoperirilor prin cromare dură , Revista Tratamente termice, Nr.5. 1993
 THE COMPARATIVE ANALYSIS OF THE BLANKING TOOL WEAR USING THE
OPTICAL METHOD BY COMPARING THE RIDGE MEASURE

Alin STĂNCIOIU*
Gheorghe GÎRNICEANU**
Gheorghe POPESCU***
* Lect. dr. eng. U.C.B, Tg-Jiu, e-mail alin@utgjiu.ro
** Prof. dr. eng. U.C.B,Tg-Jiu, e-mail girniceanu@utgjiu.ro
*** Prof. dr. eng. U.C.B,Tg-Jiu, e-mail gepo@utgjiu.ro

Keywords: cutting, lubricant, shiny, surface

Abstract: In the case of the tools for metallic materials cold trim, as a duration measure for assuring the
adequate development of the technological process both the force plug or the matrix dimensional
modifications measure are taken, but also the ridge height (the degree) which is determined by the tool wear
degree.When the degree (ridge) overcomes a certain value (prescribed through the quality requirements of
the processed pieces) the continuing use of the tool (therefore increasing its use duration) there is no longer
admitted even if the technologic process may continue. The experiment proved that the ridge measure is
directly proportional with the active elements wear.
Next, they investigated the weight of the disk plates ridges obtained by blanking with all the force
plugs used in experiments: improved 205Cr115 die, chromate OSC10 die, covered sparks OSC10 die,
nitride OSC10 die, improved OSC10 die, improved OSC10 unworn die.
In the figure 1 there are displayed the images of the cutting sections in two cases: with dry friction
(above) and with lubricated friction (the bottom part) with the increase degree 5X.

The elastic and plastic deformations area.

Fig.1 Improved 205Cr115 die 5X

The breaking area

In the resulted section after cutting, we can observe an even, shiny area, specific to plastic
deformation and an uneven area, typically for breaking.
The smallest ridges are met at the blanked disk plates with OSC10 force plug covered with sparks
and chrome.
The ridges of the disk plates blanked under dry friction conditions are more visible than those of the
disk plates obtained under conditions of dry friction. In conclusion, the OSC10 force plug covered by sparks
has had the least wear.

BIBLIOGRAPHY:

[1] Stăncioiu Alin, Cercetări cu privire la influenţa calităţii sculelor asupra proceselor tehnologice de
tăiere, Universitatea din Craiova, Teza de Doctorat, 2004
[2] Şontea, Sever., Tratamente termice şi termochimice , Editura Spirit Românesc, Craiova, 2001
[3] Şontea, Sever, Calitatea acoperirilor prin cromare dură , Revista Tratamente termice, Nr.5. 1993