Numerical Investigations of the Effect of Process Parameters on Residual Stresses, Strains and Quality of Final Product in Blanking Using SPH Method

Abstract

The shearing process such as the blanking of sheet metals has been used often to prepare workpieces for subsequent forming operations. This process consists in separating a blank from a sheet by means of a high-localized shear deformation due to the action of a punch. Blanking modelling is becoming an increasingly important tool in gaining understanding and improving this process. At the moment a fundamental problem in numerical modelling of blanking processes is an excessive element distortion in a finite-element simulation. In this study, we present a hybrid modelling approach, SPH (smoothed particle hydrodynamics) coupled FEM method to simulate the blanking process. This new approach involves several advantages compared to the traditional finite element method for example: neglect mesh tangling and distortion problems, does not need to use material separation criterion. The physical, mathematical and computer model of the process is elaborated. The application in ANSYS/LS-DYNA program is developed. The examination and analysis of influence of process technological parameters for example: the clearance, tool geometry, blanking velocity on residual stresses, strains and quality of final product using the SPH method is analyzed. The results of computer simulations can be used to forecasting quality of the parts optimization.