FINITE ELEMENT SIMULATION OF BLANKING PROCESS

The blanking process can be simulated by ABAQUS v 6.4 to select punch, die and press and ascertain punch wear and bur height. The experimental and the simulation results agree well with rising punch force up to the point of creation of crack. For a 2mm mild steel sheet, the simulation shows that for the punch force of 240 kN, the crack starts at 30% punch penetration depth and punch force suddenly drops to a value of 70 kN and remains steady till the blanking is complete. Comparing simulation and experimental results for a 3mm mild steel sheet, results agree well in the elastic range with the punch force rising up to point of crack creation. However, a discrepancy appears in punch force which increases with punch penetration. At 32% depth of penetration, the discrepancy is 12 % which increases to 60 % at punch penetration of 42%. Punch force for experimental and simulation results remains about 90kN beyond punch penetration of 62%. Also, increase of the thickness of sheet results in reduced crack height and improved quality of blank.