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(PART 1)s
1. INTRODUCTION The sheet metal forming processes in general and in particular the punching
process, often associated with relatively simple mechanical processes of low technological input and low
added value. However, the reality is very different because these processes, as well as other processes of
mechanical type, are strongly influenced by very different factors related to machine tools, material and
geometric characteristics of the piece or the environment itself process (table 1). The punching operation
is a sheet cutting or sheets, usually cold, by a mechanical device consists of two tools: the punch and die.
Applying a compressive force on the punch forcing it to penetrate the sheet, creating an initial
elastoplastic deformation regime followed by shearing and rupture of the material by rapid crack
propagation between the cutting edges of the punch and die. The process ends with the removal of the cut
piece (Figure 1)
In general , most studies on the mechanics of the process of plastic deformation and cutting, are intended
to analyze the defects that occur on the edge of the punched parts . The first results of studies on the
mechanisms of cutting punching occur in the early fifties , Germany ( Keller ) and Japan ( Fukui and
Maeda ) simultaneously. Today , studies focus on obtaining mathematical models together with the finite
element method allowing the calculation of forces, determining edge quality of the part and process
simulation .
2. ANALYSIS OF THE PROCESS OF PUNCHING
2.1 . Mechanical cutting
In the punching process can be considered three steps (Figure 2) :
Deformation efforts punch on the metal sheet , it originate deformation , elastic and then initially plastic ,
around the edges of the punch and die .
Penetration : the cutting edges of the punch and die penetrate into the material , causing cracks in the
material due to stress concentration along the cutting edges .
Fracture : cracks originated either side of the sheet are causing the separation of material. Also, the punch
continues its descent to eject the cut . The court game J , allows the penetration of the punch in the matrix
( Figure 3) and the expulsion of the cut material.
At the bottom of the punch stroke, a side cut and a second burnished area (Figure 5-B) occurs. The
decrease of the game, below normal values, causing decrease of all defects in shape, thereby improving
the accuracy of the edges obtained.
where As is calculated from the plate thickness and area and perimeter cutting lp
and ks includes game effects cutting, tool wear and the influence of other parameters such as material
properties, thickness and shape of the contour of the punch.
The shear strength by punching ks decreases with increasing cutting game, and its variation of
approximately 14% in the range of J = 0.01 0,1e. In Figure 7 shows this effect, using three different
materials and perfectly sharp punches. As punchings are performed, the punch suffers wear which results
in an increase of up to 1.6 times ks. Moreover, the cutting resistance is affected by the diameter of the
hole punching and the value of cutting resistance decreases with increasing diameter of the punch if the
other constant conditions (Figure 8) are maintained. Another influencing factor is the shape of the section
of the punch. In areas of high curvature there is a stress concentration, why is more frequent breakage of
the punch in sharp corners.
In practice , industry ks value by the maximum shear stress tB , and the maximum cutting force is
estimated by :
TB value is obtained from tables or from resistance to breakage sr . Usually taken as tB shear resistance
of a value equal to 80% of the breaking strength , however , this ratio varies with the type and thickness
of material. According to studies by Oehler , there is a linear dependence between the shear and the
logarithm of the ratio dp / e . According to these studies :
Once cut the material it must be expelled through the matrix, generally conically shaped to facilitate
removal and hinder the return of the material with recoil cut punch. The force required to overcome
friction and radial compression between the punch and the plate and between the cut piece and the
matrix. Some of these forces are also present during the return of the punch due to the friction of the
sheet with the punch. This extraction force is usually expressed as a percentage of the force required for
punching and depends on the material and cutting game.
Another factor to consider is the state of the punch. For example, blunting it suffered progressive, causing
increased cutting force, while a decrease in the recoil force.
Cutting speed also influences the shearing force. Thus, increasing the bit rate, it decreases the strength,
mainly due to elevation of the material temperature which originates with increasing strain rate.
The needled part undergoes a hardening to deform plastically, resulting in a growth of local pressures and
causing the appearance of more abrasive particles. Also it gives high production speed resulting in a high
number of impacts, favoring particle adhesion and fatigue of the cutting edges. Simultaneously increasing
the temperature of the die, the punch and the workpiece, so the adhesion is increased and oxidation is
promoted.
The elastic deformation of the part causes a relative movement along the punch face, initially outwards
and then, once initiated fracture, inwardly. This produces abrasive wear on the front face of the punch.
The treader limits this elastic deformation of the material, whereby wear of the punch is reduced.
Furthermore, the elastic recovery of the sheet produces a flank wear of the punch in the retraction
movement.
On the lateral surface of the punch and die, wear is mainly due to adhesion mechanism. Another area that
suffers wear, is the cutting edge, posing both wear mechanisms, not being remarkable the influence of the
type of tool material thereon.
The uselessness of criteria commonly used tool, are:
Energy consumption and maximum force required in the process.
Tolerable height of the burr generated in cutting.
Wear measurement of faces, sides and edges on the punch and die.
As the game increased cutting as a result of wear.
Fig . 11. Factors affecting the geometrical defects of the punched parts
It seems logical to establish standard equations of life, as in machining operations by chip removal,
which allow to know in advance the number of punches that is able to perform a set punch-matrix before
being rejected. These models allow you to set the length of the tool before reaching a value determined
wear, which will function optimization criterion chosen (minimum cost, maximum production, highest
quality, etc.). Studies on this subject are relatively rare, especially because of the complexity of the
mechanism of wear, closely linked with the life of the tool. Therefore, it is difficult to establish models
on a large database of experimental data.
2.4. Precision punched parts In the punching, as in any other manufacturing process, in necessary to
establish the accuracy specifications needed to meet user needs. It is therefore interesting to a study of
precision, in order to define the specifications, in the most accurate way possible.
The accuracy of the punched parts can be characterized by the following defects: dimensional, positional
and shape. Factors that affect these defects are mainly materials, tools, process variations and machine. In
Figure 11 the various factors affecting each of these defects are represented. Diameters and hole cutout,
measured on the polished surface, should coincide theoretically with the punch and die respectively.
These theoretical dimensions may be altered due to the influence of some factors, such as inaccuracies in
the dimensions of the tools, the elastic deformations of the elastic-they or stresses produced in the plastic
material. With respect to the positional defects, they comprise two kinds of geometrical inaccuracies:
contour irregularities and inaccuracies cutout holes punched parts. The former are usually due to lack of
coaxiality between punch and die, to defects in the guides or the inaccuracy of form tools. As for the
inaccuracy of position of the holes it depends on the accuracy of the system of movement of the plate
(Table 2).
Shape defects are those that occur at the edges of the part and tools and depend on the material. Tools
factors that most affect these geometric inaccuracies are cutting the game, the shape of the punch and the
wear of the cutting edge, while material, are quality, strength and thickness of the sheet.
Fig . 12. Different types edge depending on the game . Material steel low carbon
The value of burr height (H) is conditioned, in the case of cutting, the wear of the punch, while in the
hole, this depends on the degree of wear of the matrix. Therefore, the height of the burrs depends on the
same factors as the tool wear. Figure 13 shows the height of the burr depending on the number of
punches made.
Fig . 13. Variation of the height of the burr with the number of strokes