J. Cirne, R. Dormeval, et al.
J. Phys. IV France 134 (2006) 1189-1194
High-speed blanking of copper alloy sheets: Material modeling and simulationCh. Husson1, S. Ahzi2 and L. Daridon3
1 Institut Supérieur d'Ingénierie de la Conception, Équipe ErMEP, 27 rue d'Hellieule, 88100 Saint-Dié-des-Vosges, France
2 IMFS, UMR 7507, Université Louis Pasteur /CNRS, 2 rue Boussingault, 67000 Strasbourg, France
3 LMGC, UMR 5508, Université Montpellier II/CNRS, Place Eugène Bataillon, 34095 Montpellier, France
Published online: 26 July 2006
To optimize the blanking process of thin copper sheets (1. mm thickness), it is necessary to study the influence of the process parameters such as the punch-die clearance and the wear of the punch and the die. For high stroke rates, the strain rate developed in the work-piece can be very high. Therefore, the material modeling must include the dynamic effects.For the modeling part, we propose an elastic-viscoplastic material model combined with a non-linear isotropic damage evolution law based on the theory of the continuum damage mechanics. Our proposed modeling is valid for a wide range of strain rates and temperatures. Finite Element simulations, using the commercial code ABAQUS/Explicit, of the blanking process are then conducted and the results are compared to the experimental investigations. The predicted cut edge of the blanked part and the punch-force displacement curves are discussed as function of the process parameters. The evolution of the shape errors (roll-over depth, fracture depth, shearing depth, and burr formation) as function of the punch-die clearance, the punch and the die wear, and the contact punch/die/blank-holder are presented. A discussion on the different stages of the blanking process as function of the processing parameters is given. The predicted results of the blanking dependence on strain-rate and temperature using our modeling are presented (for the plasticity and damage). The comparison our model results with the experimental ones shows a good agreement.
© EDP Sciences 2006