PAMM · Proc. Appl. Math. Mech. 8, 10773 – 10774 (2008) / DOI 10.1002/pamm.

200810773

Optimization of the dynamic blanking process

Lukasz Bohdal∗ and Leon Kukielka∗∗
Koszalin University of Technology Raclawicka Street 15-17, 75-620 Koszalin, Poland

In this paper an optimization of the dynamic blanking process with using E-PLANNER, ANSYS and MATLAB programmes
was presented. The main aim of this work was to obtain the high quality of the cut surface in function of: the size of clearance
between punch and die, value of fillet radius of the punch edge and the speed of blanking. Numerical analysis were conducted
in Ansys LS-Dyna programme, with use of the explicit method and the experiment plan had been done before. Five levels
rotary plan, was used. Unknown coefficients in mathematical model in the shape of quadratic equation with interactions were
obtained. Obtained regression function was optimized in MATLAB programme, and determined optimal value of the process
parameters.


c 2008 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim

1 Introduction
The blanking process is one of the most commonly used ways to produce elements from sheets, and which guarantees a very
high efficiency. There exist various manners of blanking, which do not always meet the quality requirements for the product
concerning above all the accuracy of the dimensions and the shape [1]. In spite of a very large number of books and papers
concerning the blanking process, the quantity of the theoretical analysis of the process is not sufficient. On most occasions,
in order to learn about the phenomena occurring during the formation of the blanked product, experimental examinations
are conducted. In order to obtain a product with the required quality of the cut surface and the proper dimension and shape
accuracy, the process parameters are controlled. From the practical point of view, the greatest possibilities of the control of
the process can be ensured by suitably selected geometric parameters, which have a great influence on the states of stresses
and strains in the object blanked. A skilful selection of the geometric parameters of the tools, the matrix, clearance values etc.,
makes it possible to obtain a smooth cut surface, without the need of any additional machining operations. In the present paper,
the effects of the interaction between the clearance, the wear state of the tool and the speed of blanking on the geometry of the
sheared profile was presented. The quality and accuracy of blanked parts can be characterized according to possible defects,
including dimensional, positional, form and surface errors. Of these, one of the most important defects in blanking operations
are form errors, which consist of geometrical irregularities that can appear in the sheared profile of the workpiece. Indentation
zone (Se), depth of crack penetration (tc) and burr height (hb) are the most frequently considered form errors in these parts.
An aim of the optimization is finding the minimum value depth of crack penetration (tc) on product in the function: clearance
between the punch and the die, the punch radius and the speed of blanking. Decision variables used in the optimization: a -
(0.01÷0.5) mm, Rb - (0÷0.8) mm, v - (5÷50) m/s.

Fig. 1 The scheme of the test stand: t - material thickness, a - clearance, v - speed of blanking, Rb - punch radius, Se -
indentation zone, bl - burnished zone, hb - burr, hf - fracture zone

∗ Corresponding author: e-mail: Bohdall@interia.pl, Phone: +48 943 478 328, Fax: +48 943 426 753
∗∗ e-mail: leon.kukielka@tu.koszalin.pl, Phone +48 943 478 248.

c 2008 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim
10774 Sessions of Short Communications 16: Optimization

2 Numerical model
This transient problem was approached using the central-difference method and the experiment plan had been done before.
Five levels rotary plan, was used. Unknown coefficients in mathematical model in the shape of quadratic equation with
interactions were obtained.The equation describing an object’s motion and deformation at a typical time step in updated
Lagrange’s description assumes the following form [2]:

[M ]{∆r̈} + [CT ]{∆ṙ} + ([KT ] + [∆KT ]){∆r} = {∆RT } + {∆F } + {FT } (1)

where: [M ] - global system-mass matrix at time t, [CT ] - global system-attenuation matrix at time t,[KT ] - global stiffness-
increment matrix at time t, [∆KT ] - global object stiffness matrix at the step time ∆t, {FT } - global object internal load vector
at the time t, {∆F } - object internal load increment vector at the step time ∆t, {∆RT } - global object external load increment
vector at the step time ∆t, {∆r} - object site dislocation increment vector at the step time ∆t, {∆ṙ} - object site velocity
increment vector at the step time ∆t, {∆r̈} - object site acceleration increment vector at the step time ∆t. This equation is not
solvable due to number of unknowns exceeding the number of equations. An approximation by the central-difference method
has been applied to express {ṙ} and {r̈} vectors using the displacement vectors at moments t − ∆t, t, t + ∆t:

1 1
{ṙ t } = ({r t+∆t } − {r t−∆t }), {r̈ t } = ({r t+∆t } − 2{r t } + {r t−∆t }). (2)
2∆t ∆t2

3 Results of analysis
Obtained function of regression from Experiment Planner was optimized in MATLAB programme, and determined optimal
conditions of the process parameters: a = 0.01 mm, Rb = 0 mm, v = 5 m/s, tc = 0.0674 mm.

Fig. 2 a) view of the blanked product shape for optimal parameters, b) the dependence of the depth of crack penetration (tc)
from the clearance (a) and the punch edge radius (Rb), for the speed of blanking v = 5 m/s

4 Conclusions
The developed numerical investigation of the sheet metal blanking process makes it possible to study the effects of the inter-
action between the wear state of the tool, the punch - die clearance and the speed of blanking on the variation of geometry
sheared edge. The design of experiments method used in this work provides a better understanding of the blanking manu-
facturing response. Clearance has a significant influence both on the course of the blanking process and on the state of the
surface of separation. To minimize the fracture zone and the depth of crack penetration, it is preferable to set the clearance at
5 percent of the thickness of the sheet cut. The height of the burrs which is too big is the result of blanking with an unsuitable
clearance, or the result of a rounded cutting edge of the punch. In the case of blanking with minimal clearance and flat punch
receives the high quality of the blanked surface without using large speeds of blanking.

References
[1] Erbel S., Kuczynski K., Marciniak Z.: Plastic Working. PWN, Warszawa 1981.
[2] Kleiber M.: Finite Element Method in Non-Linear Continuum Mechanics. PWN, Warszawa - Poznan, 1982.

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