A Novel Force Variation Fine-Blanking Process for the High-Strength and Low-Plasticity Material

Abstract

High forming force is often needed when high-strength and low-plasticity materials are processed by fine blanking. Too high forming force increases the load of the die and greatly increases the risk of die failure. If the forming force is reduced, the material will fracture prematurely, which will lead to poor quality parts. Aiming at this problem, a new force variation load fine-blanking technology is proposed in this paper. During the loading process, the forming force does not remain constant but changes with the blanking stroke. A 2D finite element fine-blanking model was established for the TC4 material. The mechanism of force variation fine blanking is also revealed. This paper proposes a method to design the loading route of the forming force with variable load. This method combines finite element simulation with neural network and a multi-objective genetic algorithm. Finally, the application of variable load fine blanking production and the application of traditional fine blanking production parts are verified by the experimental method. The same results are obtained from both simulation and experiment. It is found that the variable load fine blanking process can greatly reduce the load of the die on the premise of ensuring the quality of fine-blanking parts.

Application of a neural network for predicting cutting surface quality of punching processes based on tooling parameters

“…[16] also employed artificial neural networks and multiple regression analysis to develop a model for predicting burr height in a shearing process. Mao et al [10] successfully predicted clean cut heights of fine-blanked parts also using an artificial neural network trained on the basis of numerically determined punch and counterpunch forces. Furthermore, machine learning models have been used several times to quantify tool wear in shear cutting processes [11]-[15].…”

Energy consumption analysis for the fine blanking process

“…However, there are few studies on the final energy demand of fine blanking, so this paper will focus on this. At present, the focus of optimizing the parameters of fine blanking is to improve the length of the shear zone [23,24], reduce the height of the die roll zone [25,26], and optimize the die structure [27,28]. Under the premise of ensuring forming quality, using finite element simulation to optimize process parameters to reduce production costs and energy consumption is an important method to achieve green fine blanking.…”