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The Effects of Punch Angle in Noise and Force Formation For Sheet Metal Blanking Process

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45 views8 pages

The Effects of Punch Angle in Noise and Force Formation For Sheet Metal Blanking Process

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nitesh
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Original article

Proc IMechE Part E:


J Process Mechanical Engineering
The effects of punch angle in noise 2022, Vol. 236(4) 1477–1484
© IMechE 2021
and force formation for sheet Article reuse guidelines:
sagepub.com/journals-permissions
metal blanking process DOI: 10.1177/09544089211063724
journals.sagepub.com/home/pie

Onur Cavusoglu1 , Hakan Gurun1, Fırat Kafkas1,


Saziye Efendioglu2 and Faruk Mert3

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

Date received: 8 July 2021; accepted: 12 November 2021

Introduction steels are used extensively, detailed research is needed


on this subject. The aim in sheet metal production pro-
In The automotive industry, advanced high-strength steels cesses is a high-quality production with minimum
(AHSSs) with low sheet thickness are preferred due to energy and time13–15.
reducing vehicle weights while increasing passenger When the studies on blanking force and noise forma-
safety. Thanks to the lightening in weight, the energy tion in literature are examined, Galdos et al. and Gürün
requirement is reduced. It causes a reduction in fuel con- et al. examined the blanking force using angled punches
sumption and as a result, the carbon footprint decreases. in their works. The blanking force was significantly
This is also an essential factor in terms of global reduced with an increasing punch angle16,17. Nothhaft
warming. For this reason, the use of advanced high- et al. determined the formation of force during blanking
strength steel sheets in automobiles has increased consid- with the chamfered punches, there was no significant
erably in recent years. Among the materials called change in force with a chamfered punch in the range of
advanced high-strength steels developed in this context, 0° to 7°, but there was a reduction in the blanking force
dual-phase steels have an important place with their with 20° chamfered punch, but the product quality was
superior mechanical properties1–6. reduced18. Mackensen et al. observed that the application
Blanking is one of the important methods used in sheet of angled punch in the blanking of advanced high strength
metal forming applications. This method is to obtain the steels (AHSS) significantly reduces the blanking force19.
product of desired geometry dimensions as a result of Kutuniva et al. performed the blanking of the DQ960
blanking of sheet metal which is placed between the ultra high strength steel sheet using convex double-sided
punch and die7,8. This process starts with the contact of angled blanking punches in the range of 0° - 14°. By
the punch on the sheet. In the meantime, elastic deform-
ation occurs on the sheet first As the punch continues to
move, elastic limits are exceeded and plastic deformation 1
Faculty of Technology, Department of Manufacturing Engineering, Gazi
starts to occur. With the increment of the punch stroke, the University, Ankara, Turkey
formation of cracks starts on the sheet, and then the blank- 2
Turkish Automotive Factory, R&D Center, Bursa, Turkey
ing occurs. The force applied to perform this operation is 3
Vocational School of Technical Science, Ankara Yıldırım Beyazıt
called the blanking force9,10. Besides, vibration and noise University, Ankara, Turkey
occur during blanking11.
Corresponding author:
Considering the sector size of the automotive indus- Faculty of Technology, Department of Manufacturing Engineering, Gazi
try12, where sheet metal forming processes are intensely University, Ankara, 06560, Turkey.
needed today and especially advanced high-strength Email: [email protected]
1478 Proc IMechE Part E: J Process Mechanical Engineering 236(4)

increasing the punch angle, the blanking force was


reduced by 57%. However, they stated that product
quality decreases20. In their study, Khleif and Jasim
examined the blanking forces by using (0°, 5°, 10°, 15°,
and 20°) angled punches. With the increase of the
punch angle, the blanking force was reduced by up to
90%21,22.
Noise formation occurs in sheet metal forming opera-
tions where press machines are used. This is one of the
main factors affecting the health of the employee.
Among sheet metal forming methods, blanking is a
process with a higher noise level than others. Tirtharaj
et al. examined the effects of noise levels on worker
comfort in various tonnage presses and reported that
high noise levels caused ear and migraine pain23. Xia
et al. examined the effect of material type, sheet thickness,
and punch speed on noise in sheet metal blanking. They Figure 1. The tensile curve of DP600 dual-phase steel.
determined that the noise level increases with the increase
in material strength, sheet thickness, and speed24. steel. In the microstructure image, the light-colored
Murakawa et al. succeeded to reduce the noise level in regions are seen as the ferrite matrix, while the dark-
the blanking by using hydraulic inertia damper25. Otsu colored areas are distributed as martensite regions.
et al. controlled the movement of the press ram and rea- Blanking force has a great influence on the product
lized a two-stage blanking operation, and decreased the quality and press stiffness29–33. In the theoretical calcula-
noise level26. Sano et al. studied noise analysis on a mech- tion of force in blanking operations, ultimate tensile
anical C-type press and calculated the sound energy to strength, blanking length, and sheet thickness are effect-
predict noise generation27. Wang et al. studied the rela- ive. Generally, in the calculation of the parallel blanking
tionship between noise level and working mechanism in force with a flat punch and die, the length of contact is
servo presses28. taken into account and the force is generated depending
It was seen that the blanking force by using the punch on this length since all the edges of the punch are in
angle could be significantly reduced. The noise formation contact. However, in blanking operations using an
had negative effects on employee health and it was under- angled punch, the blanking punch does not touch all sec-
stood that the noise level could be reduced to a small tions of the sheet at the same time, so the force is grad-
amount by various methods. ually formed depending on the punch angle.
In this study, the effects of punch angle, punch Generally, equation (1) is used for blanking with a flat
speed, and sheet thickness on the blanking force and punch, and equation (2) is used for blanking with angled
noise level were determined in the blanking of DP600 punches16.
advanced high strength dual-phase steel sheet. The
experimental results for blanking forces and noise Fc = τ ∗ S = Kc ∗ UTS ∗ L ∗ t (1)
levels were presented and the results were discussed
with the related literature.
t2
Fc = τ ∗ S = Kc ∗ UTS ∗ (2)
2 ∗ tan α
Materials and experimental procedure
In this study, the DP600 dual-phase steel sheet with a
thickness of 0.8 mm and 2 mm was used, which is
widely preferred especially in the automotive industry.
The chemical composition and mechanical properties of
the DP600 dual-phase steel sheet are presented in
Table 1 and Figure 1, respectively. Dual-phase steel’s
microstructure consists of ferrite and martensite phases.
Figure 2 shows the microstructure of DP600 dual-phase

Table 1. Chemical composition of DP600 dual-phase steel


sheet material (wt, %).

Steel Grade C Mn Ni Cr Si P S Cu Al

DP600 0.07 1.58 – 0.48 0.10 <0.02 <0.01 – 0.03


Figure 2. The microstructure of DP600 dual-phase steel.
Cavusoglu et al. 1479

Figure 3. Calculation of the blanking area.16.

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

Figure 4. Experiment setup.


1480 Proc IMechE Part E: J Process Mechanical Engineering 236(4)

Figure 7. Noise relation with punch angle and speed.

Figure 5. Noise formation for 0.8 mm sheet thickness.

Figure 8. Blanking force relation with punch angle and speed.

speed of 25 mm/min, and 70–72 dB at a blanking speed of


37.5 mm/min, respectively. At higher blanking speeds,
the pressure increase in the press hydraulic system leads
to an increase in the environmental noise level.
Figures 5 and 6 show noise formation during the
blanking. When the noise formation curves are examined,
Figure 6. Noise formation for 2 mm sheet thickness. it is seen that in the blanking operations made with 0° and
Cavusoglu et al. 1481

Figure 9. Blanking force formation curves for 0.8 mm sheet thickness.

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)

Figure 10. Blanking force formation curves for 2 mm sheet thickness.

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

Conclusions 5. Chatterjee D. Behind the development of aAdvanced High


Strength Steel (AHSS) including stainless steel for automo-
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Declaration of conflicting interests 13. Gréban F, Monteil G and Roizard X. Influence of the
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14. Mirandola I, Berti GA, Caracciolo R, et al. Machine
Funding learning-based models for the estimation of the energy con-
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The author(s) disclosed receipt of the following financial support
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This work was supported by the Gazi University, Projects of
metal production using a model-based adaptive approach.
Scientific Investigation Unit (Project No: 07/2016-02).
Procedia Comput Sci 2021; 180: 249–258.
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Onur Cavusoglu https://orcid.org/0000-0002-7239-3902 angle shearing of several steels. AIP Conf Proc 2019;
2113: 080024. DOI: 10.1063/1.5112632.
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Supplemental material for this article is available online.
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