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The technological process of the clamp part is analyzed, the design of the stamping and bending process for the clamp is introduced, including determination of the operation sequence and operation position parts dimensions. The process is used side blade settles to distance, pilot pin was used in exact positioning, the blanking and bending of the part were carried out continuously. The design of the general structure, layout of the progressive and forming characteristics die for the clamp is introduced in detail, the method for designing and calculating the key parts.

Tool steel grade JIS; SKD-11 is a well-known raw material for making a high wear resistance of blanking tool in stamping industry. One problem in the blanking process is the high cost of raw material for making punch and die. Therefore, in this study, behavior of wear phenomenon and ability of recycle on the punch of blanking die process were investigated. In the first section, phenomenon and mechanism wear of blanking punch were observed. We found that mechanism of wear on blanking punch was adhesion wear, since high amount of chromium content in the punch has compatibility of elements. The second section, recovery punch was designed by annealing, resize and quenching process by using the new punch from the first section. From the recovery punch results, it was found that the wear resistance of recovery punch decreased slightly but it was strong enough to continue in blanking process. However, the recycle process of tool steel depends on a quality and amount of the product.

This paper presents the research work involved in the development of knowledge based system (KBS) for blanking die. Automotive covering parts stamping production as one of the important chain of automobile manufacturing, especially the design of blanking die played a vital role. And the success of blanking die design often rely on the experience and knowledge of experts. And because of the knowledge of \"privacy\", new mold production designer is difficult to be familiar with the design processes and structure parameters in a short period. Such a phenomenon extended the production cycle, and increased manufacturing costs. This topic from the perspective based on knowledge, by means of integration, in view of the blanking die design of similar offers ways and means to solve the problem.

Similar to conventional blanking, there are some characteristics, such as rollover, burnish, and fracture on the sides of micro blanked parts, and rollover height and fracture height vary with the blanking clearance. This paper attempts to reveal the effect of blanking clearance on the rollover height. An uncoupled ductile fracture criterion is used to describe the effect of the blanking clearance on the fracture height. The experimental and simulation results show that the increase in hydrostatic stress gradient on the foil around the die edge results in an increase in rollover height. The coefficients of the uncoupled ductile fracture criterion are determined by the method of inverse solution and data fitting. The criterion is evaluated by mean-square error to ensure its validity. This analysis method has been verified by micro brass blanked part.

Die-Set is one of the Punching/Blanking die components. It includes lower and upper shoes, guide posts and guide bushes. The High demand of Die-Set in industry resulted in the supply of specified die set from many manufacturing companies. The standard components in the market cover only the small and medium die sizes. In many cases, the designers need to build their own die-sets especially in case of progressive die design and non-tradition die sizes. In this paper, a CAD system for building a Die-Set is discussed. This system is built using Visual Basic (VB) interfacing with AutoCAD. The system covers all Die-Sets sizes (small, medium). The proposed CAD system is prepared to work as a standalone or as a subroutine for a blanking die design CAD system. It saves time in Die-Set design operation from hours to minutes. This module is a part of a series of studies to automate the design of sheet metal working tools.

When the fine-blanking process is used, secondary grinding or processing can be omitted because the shear surface of fine-blanking parts can achieve almost zero fracture zone requirements. The primary objective of the fine-blanking process is to reduce the fracture zone depth and die roll zone width. This study used a 2.5-mm-thick central processing unit (CPU) thermal heat spreader as an example. Finite element analysis software was employed to simulate and optimize the main eight process parameters that affect the fracture zone depth and die roll zone width after fine-blanking: the V-ring shape angle, V-ring height of the blank holder, V-ring height of the cavity, V-ring position, blank holder force, counter punch force, die clearance, and blanking velocity. Simulation analysis was conducted using the L 18 (2 1 × 3 7 ) Taguchi orthogonal array experimental combination. The simulation results of the fracture zone depth and die roll zone width were optimized and analyzed as quality objectives using Taguchi’s smaller-the-better design. The analysis results revealed that with fracture zone depth as the quality objective, 0.164 mm was the optimal value, and counter punch force made the largest contribution of 25.89%. In addition, with die roll zone width as the quality objective, the optimal value was 1.274 mm, and V-ring height of the cavity made the largest contribution of 29.45%. Subsequently, this study selected fracture zone depth and die roll zone width as multicriteria quality objectives and used the robust multicriteria optimal approach and Pareto-optimal solutions to perform multicriteria optimization analysis. The results met the industry’s fraction zone depth standard (below 12% of blank thickness) and achieved a smaller die roll zone width.

Tool steel play a vital role in modern manufacturing industries due to its excellent properties. AISI D3 is a cold work tool steel which possess high strength, more hardenability and good wear resistance properties. It has a wide variety of applications in automobile and tool and die making industries such as blanking and forming tools, high stressed cutting, deep drawing and press tools. The novel ways of machining these steels and finding out the optimum process parameters to yield good output is of practical importance in the field of research. This research work explores an attempt to identify the optimized process parameter combinations in end milling of AISI D3 steel to yield low surface roughness and maximum dish angle using trochoidal milling tool path, which is considered as a novelty in this study. 20 experimental trials based on face centered central composite design (CCD) of response surface methodology (RSM) were executed by varying the input process factors such as cutting speed, feed rate and trochoidal step. Analysis of variance (ANOVA) was adopted to study the significance of selected process parameters and its relative interactions on the performance measures. Desirability-based multiple objective optimization was performed and the mathematical models were developed for prediction purposes. The developed mathematical model was statistically significant with optimum conditions of cutting speed of 41m/min, feed rate of 120 mm/min and trochoidal step of 0.9 mm. It was also found that the deviation between the experimental and predicted values is 6.10% for surface roughness and 1.33% for dish angle, respectively.

Directed Energy Deposition (DED) is an additive manufacturing process which can be used to repair defected components, such as blanking dies made of K340 tool steel. In this work, double tracks of K340 steel were deposited using DED process to study the processability of the alloy, and the tracks were characterized by light optical microscopy (LOM), scanning electron microscopy (SEM) and microhardness test. The results showed that near full-dense deposits can be made. However, the thermal cycle imposed by the process alters the microstructure of the material. Further investigation is required to make it possible to achieve a more homogeneous microstructure.

As an important forming parameter, the influence of punch-die clearance on thick plate blanking has been extensively discussed. In contrast, the analysis and prediction of metallic foil blanking are more difficult due to the size effect caused by thickness reduction. To explore the clearance effects at a meso-scale, a series of blanking tests of 304 stainless steel foils with 100 μm thickness were carried out at 5, 10, and 15 μm punch-die clearances. Corresponding working conditions were also numerical simulated, where the damage mechanism was described using an extended Gurson-Tvergaard-Needleman model while the size effect was characterized using a mechanism-based strain gradient (MSG) theory. The results indicated that damage was observed to evolve as a function of the machining process. Furthermore, shear damage was underestimated without considering the size effect, resulting in inaccurate failure punch penetration prediction. In terms of forming quality, a decrease in the clearance resulted in a proximate damage value on the punch and die side materials along with a decrease in the shear band width. The change in clearance is negatively correlated to the rollover and burnish lengths, and positively correlated to the fracture length. The introduction of the MSG theory made the simulation results more consistent with the scanning electron microscope (SEM) observations of the sheared edges. Overall, this study presented an advanced simulation method and contributes to optimal clearance selection with respect to forming quality prediction for foil blanking.

To reduce the wear of the motor rotor punching punch and ensure the efficiency is the highest in actual production, the finite element analysis software Deform-3Dv11 is used to simulate the punch wear based on the Archard model theory. With punch wear as the response target and punch speed, punch clearance, and punch edge fillet as the main factors, 17 groups of response surface Box–Behnken test designs are established, as well as a quadratic polynomial regression model between the main factors and the response. The results revealed that: the influence of various parameters on punch wear is in the order of punch edge fillet C > punch clearance B > punch speed A; the order of the interactive influence of various factors is as follows: punch speed and punch edge fillet AC > punch speed and punch clearance AB > punch clearance and punch edge fillet BC. The optimal blanking process combination obtained by using Design-Expert13 software is as follows: blanking speed 50 mm/s, blanking clearance 0.036 mm, and die cutting edge rounded corner 0.076 mm; the predicted response surface value is 6.95 × 10−12 mm. Through simulation verification, the actual optimized simulation value is 6.93 × 10−12 mm, with an absolute relative error of 2.5% for the predicted response value. Moreover, the optimized simulation value is reduced by 30.4% compared to the one before optimization, effectively reducing the punch wear of the motor rotor punching forming and providing a theoretical foundation for further wear optimization.