Tool Wear Mechanisms in Fine Blanking of JIS SPHD P/O Steel: Effects of Clearance, Cutting Speed, and Shear force on Punch and Die Degradation
Keywords:
Archard’s wear theory, Fine blanking, Process simulation, Punch-die wearAbstract
This research investigates the factors affecting punch and die wear in the fine blanking process for JIS SPHD P/O sheet metal with a thickness of 7 mm using both simulations and experimental testing. The factors considered include cutting clearance (1-5%t), Punch Speed (25-45 m/min), V-ring pressure (40-80 kN), punch and die hardness (60-68 HRC), and punch-die edge angle (20-45°). Wear analysis is based on Archard's wear theory, which evaluates volumetric wear rate under compressive forces and friction conditions. The results indicate that the optimal cutting clearance significantly reduces wear, whereas excessive clearance increases deformation and wear rate. Higher shearing speeds intensify wear due to increased temperature during the cutting process. Proper V-ring pressure enhances shear force distribution, reducing wear. Increased punch and die hardness decrease wear, but excessive hardness may lead to tool fracture. Additionally, an appropriate edge angle reduces friction and effectively minimizes punch and die wear. The simulation and experimental results show consistent trends, providing a foundation for optimizing the fine blanking process to reduce tool wear, extend die lifespan, and improve manufacturing efficiency in the sheet metal forming industry.
References
M. Yousefi and S. Pervaiz, “3D Finite element modeling of wear effects in the punching process,”. Simulation Modelling Practice and Theory, vol. 114, pp. 102415, Jan. 2022, doi: 10.1016/j.simpat.2021.102415.
M. Moghadam, M. Villa, P. Moreau, A. Dubois, L. Dubar, C.V. Nielsen, and N. Bay., “Analysis of lubricant performance in punching and blanking,”. Tribology International, vol. 141, pp. 105949, Jan. 2020, doi: 10.1016/j.triboint.2019.105949.
Y.-C. Hung, “Applying punching without die to micro-hole array processing,” Journal of Manufacturing Processes, vol. 116, pp. 284–292, Apr. 2024, doi: 10.1016/j.jmapro.2024.02.064.
M. Unterberg, H. Voigts, I. F. Weiser, A. Feuerhack, D. Trauth, and T. Bergs, “Wear monitoring in fine blanking processes using feature-based analysis of acoustic emission signals”, 54th CIRP Conference on Manufacturing Systems, Procedia CIRP, vol. 104, 2021, pp. 164–169.
J. Rizk, M. Rachik, and A. Maillard., “Finite element simulation of the complete sheet metal blanking cycle: Effect of blanking clearance on force curve and cut edge quality,” Heliyon, vol. 10, no. 9, pp. e30334, May 2024, doi: 10.1016/j.heliyon.2024.e30334.
N. Redžić, S. Winter, E. Galiev, S. Baron, C. Stein, M. Höfer, J. Regel, V. Kräusel, and M. Dix, “Influence of the cuttingedge preparation of carbide punching tools for punching of ultra-high strength steel strips,” 7th CIRP Conference on Surface Integrity, Procedia CIRP, vol. 123, pp. 268–273., 2024
M. Sahli, X. Roizard, G. Colas, M. Assoul, L. Carpentier, P.-H. Cornuault, S. Giampiccolo, and J. P. Barbe, “Modelling and numerical simulation of steel sheet fine blanking process,” 18th International Conference Metal Forming 2020, Procedia Manufacturing, vol. 50, pp. 395–400., 2020
M. Phabsimma and S. Panich, “Prediction of Tool Wear in Fine Blanking Punch with PVD Coating with TiCN for JIS.SKH51 High Speed Tool Steel Using Archard Wear Model”, Key Engineering Materials, vol. 969, pp. 115-122, 2023, doi: 10.4028/p-8xIMzS.
ASTM International, ASTM Designation: G99 – 17 Standard Test Method for Wear Testing with a Pin-on-Disk Apparatus, West Conshohocken, PA 19428-2959. USA, 2020.
M. Hanief, M.S. Charoo., (2021), “Archard’s wear law revisited to measure accurate wear coefficient considering actual sliding velocity,” Material today proceeding, vol. 47, no. 16, pp. 5598-5600., 2021, doi: 10.1016/j.matpr.2021.03.475.
Raymond G. Bayer, “Mechanical Wear Fundamentals and Testing”, 2nd, New York, U.S.A., pp. 283-287, 2004.
K. Kitamura, T. Makino, M. Nawa, and S. Miyata, “Tribological effects of punch with micro-dimples in blanking under high hydrostatic pressure,” CIRP Annals, vol. 65, no.1, pp. 249–252, 2016, doi: 10.1016/j.cirp.2016.04.133.
C. Luo, Z. Chena, K. Zhou, Xi. Yang, X. Zhang, J. Mater. Proc. Tech, pp. 254-260, 2017.
X. Qiao, A. Cheng, X. Nie, and M. Ning, “A study on die wear prediction for automobile panels stamping based on dynamic model,” The International Journal of Advanced Manufacturing Technology, vol. 97, no. 5–8, pp. 1823–1833, May 2018, doi: 10.1007/s00170-018-1811-6.
M. Davoudi, A. F. Nejad, S. S. Rahimian Koloor, and M. Petrů, “Investigation of effective geometrical parameters on wear of hot forging die,” Journal of Materials Research and Technology, vol. 15, pp. 5221–5231, Nov. 2021, doi: 10.1016/j.jmrt.2021.10.093.
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2025 Faculty of Industrial Technology, Suan Sunandha Rajabhat University
This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.
บทความที่ได้รับการตีพิมพ์เป็นลิขสิทธิ์ของคณะเทคโนโลยีอุตสาหกรรม มหาวิทยาลัยราชภัฎสวนสุนันทา
ข้อความที่ปรากฏในบทความแต่ละเรื่องในวารสารวิชาการเล่มนี้เป็นความคิดเห็นส่วนตัวของผู้เขียนแต่ละท่านไม่เกี่ยวข้องกับมหาวิทยาลัยราชภัฎสวนสุนันทา และคณาจารย์ท่านอื่นๆในมหาวิทยาลัยฯ แต่อย่างใด ความรับผิดชอบองค์ประกอบทั้งหมดของบทความแต่ละเรื่องเป็นของผู้เขียนแต่ละท่าน หากมีความผิดพลาดใดๆ ผู้เขียนแต่ละท่านจะรับผิดชอบบทความของตนเองแต่ผู้เดียว
