• Transactions of Materials Processing
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• v.9 no.2
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• pp.152-158
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• 2000

A finite element analysis has been performed to investigate the effect of die clearance on shear planes in the fine blanking of a part of automobile safety belt. For the analysis, S45C is selected as an material, which is used in manufacturing the part of automobile safety belt, and Cockcroft-Latham fracture criterion is applied. Effect of die Clearance on die-roll width, die-roll depth, burnish zone, and fracture zone has been investigated in the finite element analysis by a rigid-plastic FEM code, DEFORM-2D. From the analysis, it has been found that die-roll depth and depth of the shear plane increase with increasing die clearance. And the burnish zone decreases with increasing die clearance, but the variation of fracture zone is opposite to that of burnish zone because the increase in die clearance requires less fracture energy. Theoretical predictions are compared with experimental results. There is a good agreement between theory and experiment.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.9 no.1
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• pp.99-105
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• 2010

This study was performed to solve the breaking problem in the fine blanking(FB) process of sector gears for car seat recliner using nickel chrome molybdenum steel(SNCM220) plate. The optimal design of embossing circle is changed to oval with labors' experiences and finite element analysis. The maximum principal stress and effective strain in a forming process are analyzed by commercial finite element software to solve the problems in embossing stage of FB process. As a result of FE analysis, the maximum principal stress in forming is lower than yield point of material. It is shown from experiments in the modified die that the formed gear does not break in embossing stage.

• Transactions of Materials Processing
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• v.30 no.3
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• pp.149-156
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• 2021

Fine blanking is a high-precision process combining principles of metal stamping and cold forming. Unlike conventional metal stamping, fine blanking uses a special triple action such as V-ring force, counter force, shearing force. This study performed the effect of pocket-shaped compression molding on the mold life of the fine blanking using the 7.4mm thick SM45C material. In order to determine the lifespan of the punch and die in the fine blanking molds, a trial mold was manufactured and various punch materials were selected to perform the mold life test. A study on the life of a fine blanking mold by applying a thick plate material was experimentally performed through a mold test.

• Design & Manufacturing
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• v.15 no.1
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• pp.41-47
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• 2021

The Fine Blanking process is an effective precision shearing process that can obtain a smooth cutting surface and high product precision through a single blanking process. It is widely used in various manufacturing fields. However, shearing through this fine blanking process is only intended to minimize burrs, die rolls and fracture surfaces and does not completely remove them. Therefore, it is necessary to study the minimization of burrs, die rolls and fracture surfaces in the fine blanking process. In this study, a study was conducted on the relationship between the fracture surface and process conditions that occurred during product production using the fine blanking process. For this purpose, the shape of the V-ring indenter, the distance to the punch, and the pressure force, clearance, shear rate, and physical properties of the material were selected as process and design variables, and the relationship with the fracture surface according to each process and design condition was tested. It was analyzed through the Experimental Design Method.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.4
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• pp.108-113
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• 2013

Industrialization and modernization of the beginning of the IT industry is growing very fast. Since telecommunications industry was developed rapidly, technologies about miniaturization and high-precision of parts have been actively developed to lead information revolution. generally, the entire shear surface of the product applying fine blanking technology must be very precise. Fine blanking is used to save cost by avoiding post-processing of the product. When using press blanking, it spends a lot of money on the production by using many post-processing. Fine blanking typically used in 0.5~18 mm thick steel plate. Because a lot of post-processing cost can be used to process, except for fine blanking. In order to develop components "CHANCE CONTENTS" in the fine blanking process, the purpose of this study is to minimize the edge of the bridge, secured 95% of the material thickness of the shear surface using the 1.6 mm thickness of the material SPCC. Blanking process by introducing after changing thickness through forging process, due to change in vee-rring force and counter force, the experimental amount of depressions and flatness and the shear surface were analyzed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.40-44
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• 1999

A finite element analysis has been performed to investigate the effect of die clearance on shear planes in the fine blanking of a part of automobile safety belt. For the analysis S45$^{\circ}C$ is selected as an material which is used in manufacturing the part of automobile safety belt and Cockcroft-Latham fracture criterion is applied, Effect of die clearance on die-roll width die-roll depth burnish zone and fracture zone has been concentrately investigated in the finite element analysis. From the analytical results it has been found that die-roll width and depth of the shear plane increase with increasing die clearance. And the burnish zone has been concentrately investigated in the finite element analysis. From the analytical results it has been found that die-roll width and depth of the shear plane increase with increasing die clearance. and the burnish zone decreases with increasing die clearance but the variation of fracture zone is opposite to that of burnish zone because the increase in die clearance requires less fracture energy Theoretical predictions are compared with experimental results, There is a good agreement between theory and experiment

• Design & Manufacturing
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• v.11 no.3
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• pp.46-50
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• 2017

Press processing is one of the best machining methods capable of mass production, satisfying dimensional, shape and quality among the methods of processing a metal plate. Among them, Fine blanking is a method of obtaining a precise cross-section such as machining of the shear surface shape. In this research, Using SCP-1 and SHP-1 materials. The deformation behaviors of the material flow affecting the die height of the shear section in accordance with the position of the V-ring in the Fine blanking were compared and analyzed. Result of interpretation, It was confirmed that the force acts on the position where the material flow direction accurately forms the die roll that the material of SCP-1 is at a position of 1.5 mm and the material of SHP-1 is at 2.0 mm. As a result, it was confirmed that the state of fo1111ing the shear surface by the V-ring was excellent. Using analysis results, In the experiment, the height of the die roll was considered by applying The position of the V-ring was 1.5 mm in SCP-1 and 2.0 mm in SHP-1. As a result of comparing the height of the die rolls, the height values of the die rolls were different from each other, It has been considered that the tendency of the die rolls to coincide with each other. It is considered that the difference of the die roll height is caused by the pressure input of the V-ring. In this study, the deformation behavior of the material(In addition to the position of the V-ring, the flow direction of the material depends on the shape of the V-ring and the Indentation amount) is considered to be an important factor in determining die roll height.

• Design & Manufacturing
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• v.17 no.3
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• pp.15-20
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• 2023

In the fine blanking process, which is a press operation known for producing parts with narrow clearances and high precision through the application of high pressure, die roll often occurs during the shearing process when the punch penetrates the material. This die roll phenomenon can significantly reduce the functional surface of the parts, leading to decreased product performance, strength, and fatigue life. In this research, we conducted an in-depth analysis of the factors influencing die roll in the curvature area of the fine blanking process and identified its root causes. Subsequently, we designed and experimentally verified a die roll reduction process specifically tailored for the door latch manufacturing process. Our findings indicate that die roll tends to increase as the curvature radius decreases, primarily due to the heightened bending moment resulting from reduced shape width-length. Additionally, die roll is triggered by the absorption of initial punch energy by scrap material during the early shearing phase, resulting in lower speed compared to the product area. To mitigate the occurrence of die roll, we strategically selected the Shaving process and carefully determined the shaving direction and clearance area length. Our experiments demonstrated a promising trend of up to 75% reduction in die roll when applying the Shaving process in the opposite direction of pre-cutting, with the minimum die roll observed at a clearance area length of 0.2 mm. Furthermore, we successfully implemented this approach in the production of door latch products, confirming a significant reduction in die roll. This research contributes valuable insights and practical solutions for addressing die roll issues in fine blanking processes.

• Design & Manufacturing
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• v.10 no.1
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• pp.51-54
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• 2016

Metal sheet forming has been commonly used as the core technology in manufacturing parts of automobiles. It guarantees the highest production rate due to the process of mass production employing the press die. For precision of the product, the accuracy of the molds and its mechanic structures are considered as essential factors. One of these is fine blanking, which is utilized for the production of the metal sheet spring, with which clear sheer surfaces can be achieved in one operation from the materials. However, the current designs of press dies perform the forming analysis with the molds of rigid body, so they are focused on weight lightening by a rule of thumb. Therefore, this paper practice structural analysis about developing the semi fine-fine blanking technology. The semi fine-blanking can be run through the combination of the hydraulic cylinders and normal presses, so this paper analyze the amount of deformation according to the oil pressure. In addition, based on the plasticity of 50CrV4, the materials of the mold parts, the structural analysis and life analysis are proceeded, so they are expected to be useful as data for manufacturing the mold.