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Analytical and Experimental Investigation of Product Geometry and Dimensional Accuracy in the Punching Process of AA 1050 and AA 1070 Sheets

Year 2024, Volume: 37 Issue: 2, 939 - 951, 01.06.2024
https://doi.org/10.35378/gujs.1247964

Abstract

Punching is a widely used and economical manufacturing method. The forces that occurred during punching and the dimensional accuracies of the parts obtained from punching are significant in manufacturing processes. This study aimed to examine the cutting forces that occur in the punching process and the dimensional accuracy of the parts. AA 1050 and AA 1070 sheet materials were used in the experimental studies. Five punches with various cutting-edge geometries were employed in the punching processes. Punching operations were carried out at a constant clearance value and press speed. The geometries of the specimens obtained from the experimental studies were examined using stereo and shuttle-pix microscopes. In addition, the finite element method was used to study punching processes. The consistency of the finite element model was analyzed by comparing experimental and numerical studies. When the flat punch geometry was used, the cutting force was at its greatest. Using the largest angled punch geometry resulted in the lowest cutting force. It has been determined that the dimensional accuracy of the blank and the falling part is better when using the flat punch geometry compared to the other punches used. In addition, it was observed that experimental and theoretical studies are compatible with each other. It is thought that finite element software can provide time and cost savings in determining the cutting force of materials.

Supporting Institution

Karabuk University KBU-BAP coordination unit

Thanks

The authors thank Karabuk University for the material supply and the KBU-BAP coordination unit for their support.

References

  • [1] Çavuşoğlu, O., Gürün, H., “The Relationship of Burr Height and Blanking Force with Clearance in the Blanking Process of AA5754 Aluminium Alloy”, Transactions of FAMENA, 41: 55–62, (2017). DOI:10.21278/TOF.41105
  • [2] Li, M., “An experimental investigation on cut surface and burr in trimming aluminum autobody sheet”, International Journal of Mechanical Sciences, 42: 889–906, (2000). DOI:10.1016/S0020-7403(99)00033-8
  • [3] Golovashchenko, S.F., “A study on trimming of aluminum autobody sheet and development of a new robust process eliminating burrs and slivers”, International Journal of Mechanical Sciences, 48: 1384–1400, (2006). DOI: 10.1016/J.IJMECSCI.2006.07.007
  • [4] Ali, K.B., Demir, B., Gürün, H., Acarer, M., “Influence of Punch Shapes on Forces and Part Quality in the Punching of Explosively Welded DP600, Al1100, and DP600-Al1100 Composite Plates”, Transactions of FAMENA, 46: 58–68, (2022). DOI: 10.21278/TOF.462039222
  • [5] Myint, P.W., Hagihara, S., Tanaka, T., Taketomi, S., “Application of Finite Element Method to Analyze the Influences of Process Parameters on the Cut Surface in Fine Blanking Processes by Using Clearance-Dependent Critical Fracture Criteria”, Journal of Manufacturing and Materials Processing, 2: 26, (2018). DOI:10.3390/JMMP2020026
  • [6] Hambli, R., Richir, S., Crubleau, P., Taravel, B., “Prediction of optimum clearance in sheet metal blanking processes”, The International Journal of Advanced Manufacturing Technology, 22: 20–25, (2003). DOI:10.1007/s00170-002-1437-5
  • [7] Mucha, J., “An experimental analysis of effects of various material tool’s wear on burr during generator sheets blanking”, The International Journal of Advanced Manufacturing Technology, 50: 495–507, (2010). DOI:10.1007/S00170-010-2554-1
  • [8] Hambli, R., “Blanking tool wear modeling using the finite element method”, International Journal of Machine Tools and Manufacture, 41: 1815–1829, (2001). Doi:10.1016/s0890-6955(01)00024-4
  • [9] Gaudillière, C., Ranc, N., Larue, A., Lorong, P., “Investigations in high speed blanking: Cutting forces and microscopic observations”, EPJ Web of Conferences, 6: 19003, (2010). DOI:10.1051/EPJCONF/20100619003
  • [10] Marouani, H., Ismail, A.B., Hug, E., Rachik, M., “Numerical investigations on sheet metal blanking with high speed deformation”, Materials & Design, 30(9): 3566–3571, (2009). DOI: 10.1016/j.matdes.2009.02.028
  • [11] Yoon, J.I., Jung, J., Lee, H. H., Kim, G., Kim, S. K., “Factors governing hole expansion ratio of steel sheets with smooth sheared edge”, Metals and Materials International 22: 1009–1014, (2016). DOI:10.1007/S12540-016-6346-5
  • [12] Jaafar, N.A., Abdullah, A.B., Samad, Z., “Effect of punching die angular clearance on punched hole quality of S275 mild steel sheet metal”, The International Journal of Advanced Manufacturing Technology, 101: 1553–1563, (2019). DOI:10.1007/S00170-018-3040-4
  • [13] Lo, S.P., Chang, D.Y., Lin, Y.Y., “Relationship between the punch–die clearance and shearing quality of progressive shearing die”, Materials and Manufacturing Processes, 25: 786–792, (2010). DOI:10.1080/10426910903447295
  • [14] Cuğ, H., Khalifa, S.S.M., Gürün, H., “The Experimental Investigation of Punching of the AM60 and AZ61 Magnesium Alloy Sheets by Using Varied Punch Shapes”, Journal of Engineering Research, 11: 331–339, (2023). DOI:10.36909/JER.12813
  • [15] Gürün, H., Göktaş, M., Güldaş, A., “Experimental Examination of Effects of Punch Angle and Clearance on Shearing Force and Estimation of Shearing Force Using Fuzzy Logic”, Transactions of FAMENA, 40: 19–28, (2016). DOI:10.21278/TOF.40302
  • [16] Tekiner, Z., Nalbant, M., Gürün, H., “An experimental study for the effect of different clearances on burr, smooth-sheared and blanking force on aluminium sheet metal”, Materials & Design, 27: 1134–1138, (2006). DOI:10.1016/j.matdes.2005.03.013
  • [17] Hatanaka, N., Yamaguchi, K., Takakura, N., Iizuka, T., “Simulation of sheared edge formation process in blanking of sheet metals”, Journal of Materials Processing Technology, 140: 628–634, (2003). DOI:10.1016/s0924-0136(03)00803-3
  • [18] Rachik, M., Roelandt, J.M., Maillard, A., “Numerical simulation of sheet metal blanking predicting the shape of the cut edge”, Key Engineering Materials, 233–236: 329–334, (2002).
  • [19] Tekkaya, A.E., Bouchard, P.O., Bruschi, S., Tasan, C.C., “Damage in metal forming”, CIRP Annals, 69(2): 600–623, (2020). DOI:10.1016/J.CIRP.2020.05.005
  • [20] Sahli, M., Roizard, X., Assoul, M., Colas, G., Giampiccolo, S., Barbe J.P., “Finite element simulation and experimental investigation of the effect of clearance on the forming quality in the fine blanking process”, Microsystem Technologies, 27: 871–881, (2021). DOI:10.1007/s00542-020-04983-7
  • [21] Şen, N., Helimergin, F., Taşdemir, V., “Effects of fine blanking process on cutting surfaces of high-strength DP600 and DP800 sheets”, Ironmaking & Steelmaking, 48: 1083-1088, (2021). DOI: 10.1080/03019233.2021.1915647
  • [22] Hadi, S., Hardjito, A., Wicaksono, H., Baananto, F., Djoenaidi, R., Basoeki, P.D., “The Effect of Aluminum Profile Thickness and Type of Lubricant on Punch Force”, ATASEC 2022, 219: 213–225, (2022). DOI:10.2991/978-94-6463-106-7_20
  • [23] Kurniawan, Y., Mahardika, M., Suyitno, S., “The Effect of Punch Geometry on Punching Process in Titanium Sheet”, Jurnal Teknologi, 82: 101-111, (2020). DOI: 10.11113/jt.v82.13947
  • [24] Abe, Y., Okamoto, Y., Mori, K., Jaafar, H., “Deformation behaviour and reduction in flying speed of scrap in trimming of ultra-high strength steel sheets”, Journal of Materials Processing Technology, 250: 372–378, (2017). DOI: 10.1016/j.jmatprotec.2017.07.034
  • [25] Wojtkowiak, D., Talaska, K., “Determination of the effective geometrical features of the piercing punch for polymer composite belts”, The International Journal of Advanced Manufacturing Technology, 104: 315–332, (2019). DOI:10.1007/s00170-019-03746-7
Year 2024, Volume: 37 Issue: 2, 939 - 951, 01.06.2024
https://doi.org/10.35378/gujs.1247964

Abstract

References

  • [1] Çavuşoğlu, O., Gürün, H., “The Relationship of Burr Height and Blanking Force with Clearance in the Blanking Process of AA5754 Aluminium Alloy”, Transactions of FAMENA, 41: 55–62, (2017). DOI:10.21278/TOF.41105
  • [2] Li, M., “An experimental investigation on cut surface and burr in trimming aluminum autobody sheet”, International Journal of Mechanical Sciences, 42: 889–906, (2000). DOI:10.1016/S0020-7403(99)00033-8
  • [3] Golovashchenko, S.F., “A study on trimming of aluminum autobody sheet and development of a new robust process eliminating burrs and slivers”, International Journal of Mechanical Sciences, 48: 1384–1400, (2006). DOI: 10.1016/J.IJMECSCI.2006.07.007
  • [4] Ali, K.B., Demir, B., Gürün, H., Acarer, M., “Influence of Punch Shapes on Forces and Part Quality in the Punching of Explosively Welded DP600, Al1100, and DP600-Al1100 Composite Plates”, Transactions of FAMENA, 46: 58–68, (2022). DOI: 10.21278/TOF.462039222
  • [5] Myint, P.W., Hagihara, S., Tanaka, T., Taketomi, S., “Application of Finite Element Method to Analyze the Influences of Process Parameters on the Cut Surface in Fine Blanking Processes by Using Clearance-Dependent Critical Fracture Criteria”, Journal of Manufacturing and Materials Processing, 2: 26, (2018). DOI:10.3390/JMMP2020026
  • [6] Hambli, R., Richir, S., Crubleau, P., Taravel, B., “Prediction of optimum clearance in sheet metal blanking processes”, The International Journal of Advanced Manufacturing Technology, 22: 20–25, (2003). DOI:10.1007/s00170-002-1437-5
  • [7] Mucha, J., “An experimental analysis of effects of various material tool’s wear on burr during generator sheets blanking”, The International Journal of Advanced Manufacturing Technology, 50: 495–507, (2010). DOI:10.1007/S00170-010-2554-1
  • [8] Hambli, R., “Blanking tool wear modeling using the finite element method”, International Journal of Machine Tools and Manufacture, 41: 1815–1829, (2001). Doi:10.1016/s0890-6955(01)00024-4
  • [9] Gaudillière, C., Ranc, N., Larue, A., Lorong, P., “Investigations in high speed blanking: Cutting forces and microscopic observations”, EPJ Web of Conferences, 6: 19003, (2010). DOI:10.1051/EPJCONF/20100619003
  • [10] Marouani, H., Ismail, A.B., Hug, E., Rachik, M., “Numerical investigations on sheet metal blanking with high speed deformation”, Materials & Design, 30(9): 3566–3571, (2009). DOI: 10.1016/j.matdes.2009.02.028
  • [11] Yoon, J.I., Jung, J., Lee, H. H., Kim, G., Kim, S. K., “Factors governing hole expansion ratio of steel sheets with smooth sheared edge”, Metals and Materials International 22: 1009–1014, (2016). DOI:10.1007/S12540-016-6346-5
  • [12] Jaafar, N.A., Abdullah, A.B., Samad, Z., “Effect of punching die angular clearance on punched hole quality of S275 mild steel sheet metal”, The International Journal of Advanced Manufacturing Technology, 101: 1553–1563, (2019). DOI:10.1007/S00170-018-3040-4
  • [13] Lo, S.P., Chang, D.Y., Lin, Y.Y., “Relationship between the punch–die clearance and shearing quality of progressive shearing die”, Materials and Manufacturing Processes, 25: 786–792, (2010). DOI:10.1080/10426910903447295
  • [14] Cuğ, H., Khalifa, S.S.M., Gürün, H., “The Experimental Investigation of Punching of the AM60 and AZ61 Magnesium Alloy Sheets by Using Varied Punch Shapes”, Journal of Engineering Research, 11: 331–339, (2023). DOI:10.36909/JER.12813
  • [15] Gürün, H., Göktaş, M., Güldaş, A., “Experimental Examination of Effects of Punch Angle and Clearance on Shearing Force and Estimation of Shearing Force Using Fuzzy Logic”, Transactions of FAMENA, 40: 19–28, (2016). DOI:10.21278/TOF.40302
  • [16] Tekiner, Z., Nalbant, M., Gürün, H., “An experimental study for the effect of different clearances on burr, smooth-sheared and blanking force on aluminium sheet metal”, Materials & Design, 27: 1134–1138, (2006). DOI:10.1016/j.matdes.2005.03.013
  • [17] Hatanaka, N., Yamaguchi, K., Takakura, N., Iizuka, T., “Simulation of sheared edge formation process in blanking of sheet metals”, Journal of Materials Processing Technology, 140: 628–634, (2003). DOI:10.1016/s0924-0136(03)00803-3
  • [18] Rachik, M., Roelandt, J.M., Maillard, A., “Numerical simulation of sheet metal blanking predicting the shape of the cut edge”, Key Engineering Materials, 233–236: 329–334, (2002).
  • [19] Tekkaya, A.E., Bouchard, P.O., Bruschi, S., Tasan, C.C., “Damage in metal forming”, CIRP Annals, 69(2): 600–623, (2020). DOI:10.1016/J.CIRP.2020.05.005
  • [20] Sahli, M., Roizard, X., Assoul, M., Colas, G., Giampiccolo, S., Barbe J.P., “Finite element simulation and experimental investigation of the effect of clearance on the forming quality in the fine blanking process”, Microsystem Technologies, 27: 871–881, (2021). DOI:10.1007/s00542-020-04983-7
  • [21] Şen, N., Helimergin, F., Taşdemir, V., “Effects of fine blanking process on cutting surfaces of high-strength DP600 and DP800 sheets”, Ironmaking & Steelmaking, 48: 1083-1088, (2021). DOI: 10.1080/03019233.2021.1915647
  • [22] Hadi, S., Hardjito, A., Wicaksono, H., Baananto, F., Djoenaidi, R., Basoeki, P.D., “The Effect of Aluminum Profile Thickness and Type of Lubricant on Punch Force”, ATASEC 2022, 219: 213–225, (2022). DOI:10.2991/978-94-6463-106-7_20
  • [23] Kurniawan, Y., Mahardika, M., Suyitno, S., “The Effect of Punch Geometry on Punching Process in Titanium Sheet”, Jurnal Teknologi, 82: 101-111, (2020). DOI: 10.11113/jt.v82.13947
  • [24] Abe, Y., Okamoto, Y., Mori, K., Jaafar, H., “Deformation behaviour and reduction in flying speed of scrap in trimming of ultra-high strength steel sheets”, Journal of Materials Processing Technology, 250: 372–378, (2017). DOI: 10.1016/j.jmatprotec.2017.07.034
  • [25] Wojtkowiak, D., Talaska, K., “Determination of the effective geometrical features of the piercing punch for polymer composite belts”, The International Journal of Advanced Manufacturing Technology, 104: 315–332, (2019). DOI:10.1007/s00170-019-03746-7
There are 25 citations in total.

Details

Primary Language English
Subjects Engineering
Journal Section Mechanical Engineering
Authors

Abdullah Yetgin 0000-0003-4720-8151

Bilge Demir 0000-0002-3617-9749

Hakan Gürün 0000-0001-6189-6830

Khalil Belras Ali 0000-0003-4837-1671

Early Pub Date February 19, 2024
Publication Date June 1, 2024
Published in Issue Year 2024 Volume: 37 Issue: 2

Cite

APA Yetgin, A., Demir, B., Gürün, H., Ali, K. B. (2024). Analytical and Experimental Investigation of Product Geometry and Dimensional Accuracy in the Punching Process of AA 1050 and AA 1070 Sheets. Gazi University Journal of Science, 37(2), 939-951. https://doi.org/10.35378/gujs.1247964
AMA Yetgin A, Demir B, Gürün H, Ali KB. Analytical and Experimental Investigation of Product Geometry and Dimensional Accuracy in the Punching Process of AA 1050 and AA 1070 Sheets. Gazi University Journal of Science. June 2024;37(2):939-951. doi:10.35378/gujs.1247964
Chicago Yetgin, Abdullah, Bilge Demir, Hakan Gürün, and Khalil Belras Ali. “Analytical and Experimental Investigation of Product Geometry and Dimensional Accuracy in the Punching Process of AA 1050 and AA 1070 Sheets”. Gazi University Journal of Science 37, no. 2 (June 2024): 939-51. https://doi.org/10.35378/gujs.1247964.
EndNote Yetgin A, Demir B, Gürün H, Ali KB (June 1, 2024) Analytical and Experimental Investigation of Product Geometry and Dimensional Accuracy in the Punching Process of AA 1050 and AA 1070 Sheets. Gazi University Journal of Science 37 2 939–951.
IEEE A. Yetgin, B. Demir, H. Gürün, and K. B. Ali, “Analytical and Experimental Investigation of Product Geometry and Dimensional Accuracy in the Punching Process of AA 1050 and AA 1070 Sheets”, Gazi University Journal of Science, vol. 37, no. 2, pp. 939–951, 2024, doi: 10.35378/gujs.1247964.
ISNAD Yetgin, Abdullah et al. “Analytical and Experimental Investigation of Product Geometry and Dimensional Accuracy in the Punching Process of AA 1050 and AA 1070 Sheets”. Gazi University Journal of Science 37/2 (June 2024), 939-951. https://doi.org/10.35378/gujs.1247964.
JAMA Yetgin A, Demir B, Gürün H, Ali KB. Analytical and Experimental Investigation of Product Geometry and Dimensional Accuracy in the Punching Process of AA 1050 and AA 1070 Sheets. Gazi University Journal of Science. 2024;37:939–951.
MLA Yetgin, Abdullah et al. “Analytical and Experimental Investigation of Product Geometry and Dimensional Accuracy in the Punching Process of AA 1050 and AA 1070 Sheets”. Gazi University Journal of Science, vol. 37, no. 2, 2024, pp. 939-51, doi:10.35378/gujs.1247964.
Vancouver Yetgin A, Demir B, Gürün H, Ali KB. Analytical and Experimental Investigation of Product Geometry and Dimensional Accuracy in the Punching Process of AA 1050 and AA 1070 Sheets. Gazi University Journal of Science. 2024;37(2):939-51.