FEM analysis on the influence of rounded tool edge on micro-blanking of thin foil with negative clearance

Abstract

This work studies the effects of the tool edge radius in a micro-blanking process with negative clearance by using finite element method. For the study, a simulation model of blanking of AL6061-T6 foil with tools (punch and die) having a large edge radius comparable to the thickness of the foil was prepared. Using the model, micro-blanking process with various tool edge radii are simulated to study the resultant blanking forces and blank quality. From the simulation studies, it is found that a large edge radius of a blanking punch have effect on the blanking forces. Especially, a projecting edge was observed at the edge of the finished blank. This projecting edge is considered to be caused by negative clearance and a large edge radius of a die. Overall summary and discussion on the effect of a rounded tool edge on the blanking force and blank deformation is presented.