Numerical and experimental analyses of punch wear in the blanking of copper alloy thin sheet

Abstract

a b s t r a c tThis research on punch wear resulting from the blanking of copper alloy thin sheet has been conducted by means of experimental and numerical analyses. Firstly, the experimental method has consisted in measuring punch worn profiles from replicas, and secondly in obtaining the wear coefficient by using a specific tribometer. The numerical modelling of blanking process has been developed with the finite element method to compute the mechanical fields necessary to calculate wear. Thus, the Archard formulation for abrasive wear has been programmed to compute the wear depth and the resulting punch geometry. Finally the simulation results of wear prediction have been compared to experimental ones.

Prediction of abrasive punch wear in copper alloy thin sheet blanking

“…As mentioned in Falconnet et al [10], abrasive wear has been quantified not only by determining a wear coefficient for the studied material couple, but also by measuring punch profile.…”

“…After a determined sliding distance, the spherical pin has been removed from the tribometer to measure its volume using the 3D topographic acquisition method. The detailed procedure has been described in Falconnet et al [10]. The wear data from this tribological test are listed in Table 3.…”

“…Moreover, Hambli [9] has implemented a wear prediction model within finite element (FE) code to predict punch wear during steel metal sheet blanking, and has also investigated the effect of tool wear on burr formation. More recently, Falconnet et al [10] have combined experimental and numerical analyses to study punch wear in the blanking of copper alloy thin sheet used to produce leadframes. In this study, the material behaviour has been modelled with an elasto-plastic law without considering material damage.…”

“…In this paper, investigations on punch wear prediction presented in Falconnet et al [10] have been extended by introducing a finite element blanking model including crack initiation and propagation within blanked sheet by means of shear failure model. Data of the studied blanking configuration and wear measurements have been determined from experimental results.…”

Influence of blade profile of disc cutter on numerical simulation of the disc slitting process

“…Tool wear in machining process is inevitable and wear regions vary with the difference of the machining method and tool shape. The side faces of punch and slitting disc have serious wear [4,5], while the wear of the rank face of slitting disc with inclined rank face is serious [6]. The uneven tool wear will result in irregular shape of tool profile.…”