The Effects of Punch Angle in Noise and Force Formation For Sheet Metal Blanking Process
The Effects of Punch Angle in Noise and Force Formation For Sheet Metal Blanking Process
Abstract
The paper is concerned with the effect of punch angle (0°, 4°, 8°, 16°), sheet thickness (0.8, 2 mm), and punch speed
(25, 37.5 mm / min) on the force formation and noise in the blanking of DP600 dual-phase steel sheet. The blanking
experiments were carried out in a modular blanking die. The blanking force and noise variables were obtained simultan-
eously during the blanking using a load cell and noise measuring device, respectively. It was determined that the blanking
force significantly decreased with an increasing punch angle, while noise formation decreased. The increase in the punch
speed slightly increased the amount of noise while it did not affect the blanking force significantly.
Keywords
punch angle, punch speed, noise, blanking force, dual-phase steel, DP600, sheet metal
Steel Grade C Mn Ni Cr Si P S Cu Al
Herein, τ is the shear stress, S is the section zone that is In the experiments, blanking punches with a diam-
calculated with L is the blanking length and t is the eter of Ø 20 mm were used at 4 different punch
sheet thickness, Kc is the specific blanking factor that angles such as 0°, 4°, 8°, and 16°. The clearance
relates to the shear stress with the UTS, the Ultimate value was kept constant and it was chosen as
Tensile Stress. It is needed to calculate the Kc value for 0.16 mm and the die diameter is Ø 20.32 mm. To
specific sheet material with a given thickness and reduce the error margin, the experiments were
blanked with a known punch angle in the experiments repeated three times and the average values were
in which the blanking force can be measured16. The sche- taken.
matic images of the flat punch and angled punch during
the blanking are given in Figure 3.
The experiments were carried out on a speed-
controlled hydraulic press. With a load cell connected
Results and discussion
to the blanking die, the vertical force formed during As a result of the blanking experiments, force and noise
blanking was measured. A picture of the test setup is formation were examined depending on the punch
shown in Figure 4. The signals coming from the load speed, sheet thickness, and punch angle. Noise formation
cell were amplified by an amplifier and transferred to is an extremely important factor in terms of occupational
the analog-digital converter and then to the computer. safety. In this respect, it is desirable to minimize the noise
With the calibration, the amount of force corresponding in the industry.
to the voltage changes caused by the load cell was The noise level of the environment was measured
determined: before the experiments between 68–70 dB at a blanking
4° angled punch, the noise first decreases again by reach- speed is evaluated, it is seen that higher noise occurs at
ing a certain amount, and then the increase in the amount high punch speed. This situation is also described by
of noise continues to reach the maximum level. In this Xia et al.24 with the results obtained in their study.
case, the noise that occurred in the first stage is considered The relationship between the punch angle and speed
as the noise that occurs at the beginning between the crack with the blanking force is presented in Figure 8. It is
and the movement of the punch in the guide plate. The clearly seen that the blanking force decreases with an
noise formed at the next stage was evaluated that the increasing punch angle. This case shows that the blanking
noise occurred during the separation of the sheet by blank- force can be reduced by using angled punches, in particular
ing. In the case of blanking with 8° and 16° angled for the use of low capacity presses for blanking advanced
punches, noise formation increased only up to a high strength sheets. However, after the 8° punch angle,
maximum point. This is thought to be due to fact that it was found that there was no dramatic decrease in the
the blanking gradually spread to different areas of the amount of blanking force reduction with increasing
sheet in this punch angle range (8°–16°). punch angle. In the study of Jasim and Kheleif, it was
Figure 7 shows the relationship between noise, punch not seen a significant reduction in the blanking force at
angle, and speed. In the blanking experiments performed the increased blanking angle after the 10° punch angle22.
between 0° and 8° punch angles, it was determined that When the effect of blanking speed on the resulting
the amount of noise decreased due to the increase in the blanking force is evaluated, in some experiments higher
punch angle. The lowest noise level was observed in the blanking speed has been obtained at increasing blanking
blanking using a punch angle of 8°. However, no signifi- force, but increasing blanking speed does not cause a sig-
cant change was observed in the amount of noise at the nificant increase. For this reason, it is possible to say that
thickness of 0.8 mm in the blanking made with 16° blanking at a higher speed has no considerable effect on
angled punch, but it was determined that there was the formation of force. The results were given in the
some tendency to increase for 2 mm sheet thickness. studies of Slavič et al.34 and Gaudillière et al.35 also sup-
When the change of noise depending on the punch ported this finding.
1482 Proc IMechE Part E: J Process Mechanical Engineering 236(4)
The blanking forces that occur during the blanking was seen to expand considerably. With an 8° angled
are measured at different punch angles and speeds. punch, it is possible to say that the blanking takes
Blanking force formation curves were obtained by col- place in two stages. In this case, the force formation at
lecting data by load cell and they are given in Figure 9 the punch from the entry stage of the sheet was observed
and Figure 10. When the effect of punch speed was ana- and a certain part of the sheet was blanked at this stage. It
lyzed, it was found that the amount of blanking force did was thought that the other side of the sheet was blanked
not change significantly but the formation of the blank- as the punch continued to move. When the blanking
ing force was spread to a more extended process due made with a 16° angled punch is examined in
to needing more time interval at the lower speed. It is Figure 9d and Figure 10d, it is seen that the blanking
seen that the blanking forces formed by the 0° blanking was realized in two stages similar to the 8° angled
punch given in Figure 9a and Figure 10a are higher than punch but it is performed with a slightly lower force.
the other punch angles and the blanking force reaches the Also, the lowest blanking force was obtained at a 16°
highest point in a much narrower range. In Figure 9b and angled punch. Figure 9 and Figure 10 show that the
Figure 10b, it is observed that the blanking force forma- increase in the punch angle causes the blanking force
tion range is expanded while the blanking force con- to decrease significantly. Also, it is understood from
tinues to decrease with the 4° angled punch. It is also the blanking force formation process that the punch
clear that the necessary punch stroke length increases speed does not have a significant effect on the blanking
due to the increase in the punch angle. When the blank- force.
ing forces formation is evaluated with the 8° angled Although the use of angled punches has positive
punch given in Figure 9c and Figure 10c, a very different effects on noise formation and blanking force, there are
blanking force formation is observed compared to the also some disadvantages. It generally causes the stroke
other angled punches. The blanking force first increased length to prolong and the blanking time to increase. In
and decreased again, and then repeatedly increased and addition, some geometric defects were observed on the
decreased again. The blanking force formation range blanked piece (scrap side).
Cavusoglu et al. 1483
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