Numerical Simulation of Fine Blanking Die Wear and Die Performance Analysis

Abstract

In order to study the die wear law of rotary fine blanking helical cylindrical gear, a three-dimensional rigid plastic finite element model of rotary fine blanking helical cylindrical gear is established on the Deform-3D software platform. Based on the Archard wear model, this paper analyzes the die wear in the fine blanking process, obtains the wear distribution of each point on the working surface of the die, determines the maximum wear area, and makes a comparative analysis with the fine blanking die wear of spur gear. Through the single factor variable method, this paper studies the effects of reverse jacking force, blank holder force, blanking speed, punch and die clearance, die fillet radius, and die initial hardness on die wear. The test results show that when the punch reduction is the same, the wear of the female die of fine blanking helical cylindrical gear is greater than that of fine blanking spur cylindrical gear. When the counter jacking force increases from 100 kN to 200 kN, the maximum wear of the die gradually increases from 6.91 × 10–6 mm to 9.38 × 10–6 mm; when the blank holder force increases to 3/4 of the blanking force, the die wear decreases with the increase of blank holder force; it is ideal when the blanking clearance is 0.5% t (0.02 mm). Conclusion. The wear model can accurately predict the relationship between main process parameters and wear in the process of rotary fine blanking, and the measures to reduce die wear are put forward from the aspect of process design.