An Application of Finite Element Method and Design of Experiments in the Optimization of Sheet Metal Blanking Process

Metal blanking is a widely used process in high volume production of sheet metal components. The main objective of this paper is to present the development of a model to predict the shape of the cut side. The model investigates the effect of potential parameters influencing the blanking process and their interactions. This helped in choosing the process leading parameters for two identical products manufactured from two different materials blanked with a reasonable quality on the same mold. Finite Element Method (FEM) and Design of Experiments (DOE) approach are used in order to achieve the intended model objectives. The combination of both techniques is proposed to result in a reduction of the necessary experimental cost and effort in addition to getting a higher level of verification. It can be stated that the Finite Element Method coupled with Design of Experiments approach provide a good contribution towards the optimization of sheet metal blanking process.