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Improvement of Punch and Die Life and Part Quality in Blanking of Miniature Parts

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Improvement of Punch and Die Life and Part Quality in Blanking of Miniature Parts DISSERTATION Presented in Partial Fulfillment of the Requirements for the Degree Doctor of Philosophy in the Graduate School of The Ohio State University By Soumya Subramonian Graduate Program in Mechanical Engineering The Ohio State University 2013 Dissertation Committee: Dr.Taylan Altan, Advisor Dr.Blaine Lilly, Advisor Dr.Gary L.Kinzel Dr.Jerald Brevick Abstract Blanking or piercing is one of the most commonly used sheet metal manufacturing processes in the industry. Having a good understanding of the fundamentals and science behind this high deformation shearing process can help to improve the tool life and blanked edge quality in various ways. Finite Element Modeling of the blanking process along with experimental testing is used in this study to study the influence of various process parameters on punch and die life and blanked edge quality. In high volume blanking and blanking of high strength materials, improving the tool life can save not only tool material but also change over time which can take up to a few hours for every change over. The interaction between punch, stripper plate and sheet material is first studied experimentally since a fundamental understanding of the behavior of these components at different blanking speeds is very essential to design robust tooling for high speeds. A methodology is developed using the experimentally obtained blanking load and FEM of blanking to obtain flow stress data of the sheet material at high strains and strain rates. This flow stress data is used to investigate the effects of various process parameters on tool stress and blanked edge quality. The influence of all these parameters on tool stress, blanking load and blanked edge quality are studied. Some factors are found to influence the tool stress and blanked edge quality more than others. Parameters like punch-die clearance, punch corner radius, application of stripper pressure and blanking velocity affect the blanked edge quality. As punches and dies wear, the punch-die clearance and punch corner radius increase, causing the blanked edge quality to deteriorate by increasing the rollover and burr. Punch-die clearance along with other factors like lubrication conditions, sheet material, tool material and coating also affects the rate of tool wear. The punch ii tip geometry significantly affects the blanking load. For a given sheet material, tool material and punch geometry, can selecting the right punch-die clearance minimize punch wear? Since small radii in the punch geometry wear or chip earlier and more often than the straight edges, there is also non-uniform wear pattern observed in the punch due to the non-uniform stress on the punch. The effect of punch geometry on punch wear is studied by conducting FE simulations of blanking and correlating the punch stress obtained from FEM and punch wear obtained via experiments. The effect of sheet material and thickness on punch stress is also studied. In addition, the effect of punch-die clearance for different geometries is investigated. After having a good understanding of the relation between punch geometry and punch wear for different sheet materials, a guideline for selecting the most suitable punch-die clearance for a given punch geometry to have more uniform wear on the punch is suggested. The performance of geometry dependent variable punch-die clearance and commonly used uniform punch-die clearance is compared by conducting blanking experiments and comparing the wear patterns for both cases. It was observed that the tooling with variable punch-die clearance could punch almost three times more parts (350,000 parts) with significantly less but more uniform wear on them than the tooling with uniform clearance (126,000 parts). Methods to improve part edge quality by using the optimum stripper pressure and to improve tool life using geometry-dependent variable punch-die clearance are suggested in this study. iii Acknowledgements I am very grateful to my advisor, Dr.Taylan Altan for giving me the opportunity to pursue my graduate studies under his guidance. His intellectual support, encouragement, and guidance are the main reasons for this research work to even be possible. I sincerely thank my co-advisor, Dr.Blaine Lilly, for all his inputs and support. I thank my committee members Dr. Gary L. Kinzel and Dr. Jerald Brevick for their inputs, discussions and support. I would like to thank Bogdan Ciocirlan and Craig Campbell from Tyco Electronics Corporation for providing all the support, especially for providing the facility for conducting experiments required for my study. I thank my colleagues of the CPF, Adam Groseclose, Eren Billur, Tingting Mao and Xi Yang for the discussion and assistance during the course of my study. I thank my family and friends for all their support in this endeavor. iv Vita 2006…………………………………………B.E Mechanical Engineering, Anna University, India 2009…………………………………………M.S Mechanical Engineering, The Ohio State University 2010 to present…………………………….PhD Mechanical Engineering, The Ohio State University Publications 1. Subramonian, S. (2012). Blanking. In A. E. T. Taylan Altan (Ed.), Sheet metal forming: Processes and applications (1st edition ed., pp. 1). USA: ASM International. 2. Subramonian, S and Kardes.N. (2012). Material for Sheet Forming. In A. E. T. Taylan Altan (Ed.), Sheet metal forming: Fundamentals (1st edition ed., pp. 73). USA: ASM International. 3. Subramonian, S., Kardes, N., Demiralp, Y., Jurich, M., and Altan, T., "Evaluation of Stamping Lubricants in Forming Galvannealed Steels for Industrial Application", Journal of Manufacturing Science and Engineering, 2011, vol. 133, issue 6. 4. Subramonian, S., and Altan, T., “Punch Wear in Blanking – Part I”, Stamping Journal, July/Aug 2012, p. 14 5. Subramonian, S., and Altan, T., "Punch Wear in Blanking - Part II", Stamping Journal, Sept/Oct. 2012, p.10 v Fields of Study Major Field: Mechanical Engineering vi Table of Contents Abstract ............................................................................................................................................ ii Acknowledgments ........................................................................................................................... iv Vita ................................................................................................................................................... v List of Tables ................................................................................................................................... xii List of Figures ................................................................................................................................. xiv CHAPTER 1: Introduction ........................................................................................................... 1 1.1. Blanking Process ............................................................................................................. 2 1.2. Part Edge Characteristics ................................................................................................ 3 1.3. Punch/Die Wear ............................................................................................................... 4 CHAPTER 2: Research Objectives and Approach .................................................................... 5 CHAPTER 3: State-of-the-art review .......................................................................................... 7 3.1. Fundamentals in blanking – effect of various process parameters on punch life and blanked edge quality..................................................................................................................... 7 3.1.1. Effect of punch-die clearance ................................................................................... 7 3.1.2. Effect of punch corner radius [Picas, 2010] ........................................................... 12 3.1.3. Effect of stripper pressure on blanked edge quality of thin parts ........................... 13 3.2. Punch materials and coatings ........................................................................................ 15 3.2.1. Different Punch Materials and Coatings Used in Blanking .................................... 15 3.2.2. Comparison of WC punches with Ceramics (Y-TZP) [DiRuggiero 2000] .............. 19 3.2.3. Environmentally Benign Tribo-systems for Metal Forming [Bay, 2010] ................. 20 3.2.4. Improving the wear resistance of tools for stamping [Straffelini 2010] .................. 20 vii 3.3. Material model and fracture model used in simulations ................................................. 21 3.3.1. Material Model ........................................................................................................ 21 3.3.2. Fracture Model ....................................................................................................... 21 3.4. Punch failure – simulation modeling and experiments .................................................. 22 3.4.1. Punch Failure Mechanisms .................................................................................... 22 3.4.2. Factors affecting tool wear and galling [Billur, 2009] ............................................. 26 3.4.3. Wear Models .......................................................................................................... 26 3.4.4. Effect of tool wear on part edge quality .................................................................
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