Published Paper Details:

During the past decade, two clear trends have been observed in the production of metal components. Firstly, time-to-market needs to be shortened in order to introduce new products competitively. Secondly, ongoing miniaturization forces product dimensions to decrease. Of all forming processes employed in high volume production, blanking is one of the most widely used separation techniques. In blanking processes, tolerances on the machined parts become tighter, the focus shifted on analysis of factors that will affect in blanking process. Metal blanking is a widely used process in high volume production of sheet metal components but after blanking, burr formation at edges of the product is observed and hence it is need to do the deburring process due to this there is increasing the cost of production and time. Fine blanking is process which helps us to minimize the burr size. The main objective of this work is to present the development of a model to predict optimum value of parameter for fine blanking process. The model investigates the effect of potential parameters influencing the blanking process and their interactions. This helped in choosing the process leading parameters for two identical products manufactured from two different materials blanked with a reasonable quality on the same mold. Finite Element Method (FEM) and Design of Experiments (DOE) approach are used in order to achieve the intended objectives. It can be stated that the FEM coupled with a DOE approach provide a good contribution towards the optimization of sheet metal blanking process. In this work we study the effect of four factors on Burr height of the product i.e. Thickness, clearance, Blank holding force and material in which we get the minimum burr height of 6.818181818% of metal sheet thickness for aluminum with maximum stress 290Mpa and maximum burr height of 25% of metal sheet thickness for SS304 with maximum stress 1148.7Mpa. Minimum burr height is observer at 0.5mm thickness ,0.05 clearance and 2000 BHF shows us that the four factor directly influence the burr height of the final product.