Numerical Modelling of High Speed Blanking Considering Thermoviscoplastic Effects

Abstract

To achieve the required specifications of the cut-edge profile of a blank, a time consuming trial and error procedures based on empirical information are utilized. However, the modern industry demands high quality product specifications in the shortest possible production time. Therefore, in order to predict the cut-edge profile and speed up the production process, it is essential to develop a reliable numerical model of the high speed blanking process which can predict the cut-edge profile of the blanks. In this study, the Lagrangian based finite element (FE) approach was used to model large strain deformation that takes place in the shearzone during blanking. However, the large deformation is difficult to model using Lagrangian approach as it leads to a severe distortion of the FE mesh. Therefore, in order to overcome a premature termination of the analysis due to the mesh distortion, an adaptive remeshing and rezoning technique was developed. Furthermore, to model the ductile fracture, the discrete crack propagation method was implemented in the MSC.Marc® Due to high speed of the cutting stamp, thermoviscoplastic material behaviour has to be taken into account. The Johnson-Cook plasticity model was used to model viscoplasticity. The results obtained from the FE analysis are presented in this paper.