MATHEMATICAL MODEL DEVELOPMENT & CLEARANCE OPTIMIZATION IN SHEET METAL BLANKING PROCESS FOR COPPER (KEY IJP************854)

• Laxman Tukaram Tambe,Mirza Umead Sadattulla

Abstract

Blanking process is widely used process in sheet metal production industries to fabricate components. The sheet metal blanking industry is facing an increasingly competitive global market. Due to shortage of experienced operators and unavailability of affordable CADCAM systems, it is difficult to predict optimum clearance between punch and die to obtain high quality in small scale industries. Blanking is metal fabricating process and it is characterized by complete material separation. It is difficult to simulate the shearing process because of the narrowness of the shear band formed and the lack of an appropriate fracture criterion. The effect of potential parameters like thickness of sheet, punch-die clearance, tool wear, and punch geometry is studied to investigate their interactions on blanking process. It is important to choose process leading parameters such that two identical products from two different materials can be manufactured on same mold with high quality. This study will help to investigate the effect of sheet thickness, punch-die clearance and type of material on blanking process and will help to predict optimal set of parameters to obtain reasonable quality. A mathematical model of blanking process is developed and design of experiments method is used to predict optimum punch-die clearance for copper which will result into high quality of component.