Designing A Punch And Die Cutoff Tool

Introduction

Dies are considered to be important tools that play a significant role in the industry because they have the ability to manufacture large quantities of highly accurate identical products in a short time. In the last decade, with the rapid development of technology, compound dies are used extensively in the sheet metal industry. The compound die can implement two or more cutting or forming or both operations in a single press stroke.¹ The piercing punches are regarded as one of the main parts of the die. Therefore, an investigation of these tools will be beneficial to industry to deliver products at low prices.

Previous researches have focused on design and analysis of compound dies theoretically and numerically using manufacturing standards and simulation software. However, there is no investigation available about the optimization of cutting profile geometry for a piercing punch of a compound die. A large number of previous articles presented optimization of variables such as sheet material, clearance, tool profile, design, and product shape for blanking, drawing, deep drawing, extrusion, and forging dies.^2–7 Nevertheless, there is no credible study available in relation to the optimization of the compound die parameters. Different investigations have reported about measuring of burr heights of various sheet metals in single cutting process for optimization of the blanking parameters.^8,9 However, there are no findings related to burr formations of the product in double cutting operation for optimizing the blanking and piercing parameters in a single press cycle.

The first compound dies to be employed for punching and blanking of circular blanks and rotor laminations were invented by Gilev et al.¹⁰ The authors mention that the dies were mainly used in a horizontal/slight inclined plane. A compound die assembly was invented by Iwata¹¹ to perform blanking and piercing of large size parts having several complicated holes and slits. Nevertheless, volume and weight of the compound die have been increased.

Potocnik et al.¹² developed an automated system using computer-aided design (CAD) software for designing a compound die to produce a circular washer. Nevertheless, the authors did not interpret the final results adequately and provide enough evidence about results, but they have mentioned some experiments without adequate information. Artificial neural networks (ANNs) and finite element analysis (FEA) have been employed by Kashid and Kumar¹³ to establish a model which can be utilized to predict the life of the compound die in a relatively short computing time. However, the high complexity level of the model leads to an increase in neurons number in the hidden layer which is used to develop their ANN model, and this means an increase in solution time.

The CAD technique which was developed by Kashid et al.¹⁴ was used with assistance of an expert system of compound die parts selection for performing the automatic modeling of the die. Nevertheless, the proposed system has several disadvantages such as large amounts of information need to be entered manually, changes cannot be completed using conventional methods, and complex models take a long time to solve. Singh et al.¹⁵ attempted to model and analyze various blanking and piercing tools in a static state using finite element method (FEM). However, it is preferable to use dynamic conditions to simulate the blanking or piercing process for obtaining more accurate results.

The investigation about the influence of different cutting edges of the piercing tool on shear force and punch distortion was achieved by Singh et al.¹⁶ using FEM. However, the cutting process efficiency is decreased as the piercing force is reduced and the punch penetration through the sheet metal is increased. The effects of various cutting profiles of punching tools on the piercing process of large thickness steel sheet for making holes have been investigated by Luo.¹⁷ Nevertheless, the final product quality decreased because of the distortion of the product and increase in burr height. The effect of punch cutting edge radius and die rollover height on sheared product quality was investigated by Leung et al.¹⁸ using fine blanking process of various materials. However, it is found that the shearing edge shape of the punch did not provide significant influence on the rollover height of the top surface of selected materials.

FEM has been used by Ha et al.¹⁹ to analyze several parameters related to cutting process and blanking punch, and these have high effect on burr formation in zircaloy-4 sheet. Nevertheless, product failure possibility is increased because the burr height value is raised by three times when using the punch which has 0.3-mm corner radius. Dhoble et al.²⁰ employed FEA and Taguchi method to optimize the blanking process based on burr height of different sheet metals. However, the authors did not provide data related to punch and die material, properties of carbon steel sheet metal, and cutting speed.

Patil and Kadlag²¹ investigated the effect of clearance, sheet metal type, and thickness on burr heights of the sheet in the blanking process using FEA. The authors used Taguchi method to optimize the blanking parameters. The proposed methodology required large amounts of data to be generated for obtaining accurate results. It consumes long solution time and high cost in terms of computerized resources. The effect of clearance, sheet metal type, and thickness on burr formation has been studied by Quazi and Shaikh²² using FEA. The authors used Taguchi method to predict the blanking parameters optimization, cutting edge shape, and burr heights of the product. The paper did not include information about punch and die dimensions with their material properties, product shape, and sheet metal properties.

In this article, an attempt is made to address the shortcomings mentioned above in developing an efficient compound die. The investigation focuses primarily on studying the effects of dependent and independent parameters used toward the product quality using various piercing punches of the compound die. Two models of compound dies have been designed to implement double cutting process (piercing and blanking) in one stroke of the press. The results obtained contribute to the optimum design of the compound die.

Design procedures

Comprehensive design of the compound die was achieved based on manufacturing data and recommended standards. The design methodology consists of several steps, as outlined in Figure 1 , to develop the compound die which can be used to produce the exhaust gas recirculation (EGR) plate. This product can be produced at various thicknesses such as 1, 1.5, and 2 mm, and its shape dimensions are indicated in Figure 2 . Two different materials, including carbon steel AISI 1018 and stainless steel AISI 202, were selected for this study. The properties of both sheet metals are shown in Table 1.

Figure 1. Methodology of compound die design for producing EGR plate.

Figure 2. Dimensions of EGR plate (in mm).

Table 1. Properties of steel 1018 and stainless steel 202.23–26

The cutting force of the blanking and piercing process was computed using the following equation²⁷

The cutting force details are indicated in Table 2. The stripping force which is required to calculate the minimum stripper spring force can be calculated utilizing the following formula²⁸

Table 2. Cutting force, stripping force, press capacity, and press tonnage.

The stripping force details are shown in Table 2. The total press capacity was determined by the combination of the cutting and stripping force.²⁹ For design safety, the total press tonnage was identified by dividing the total press capacity by 70%.²⁹ The values of the total press capacity and tonnage are presented in Table 2.

The product orientation on sheet metal is dependent on the width of sheet material. When the sheet thickness is larger than 0.6 mm, the horizontal distance between two edges of two blanks is assumed to be 6 mm for sheet metal thicknesses including 1, 1.5, and 2 mm.³⁰ The vertical distance from edge of the blank to side of the sheet is assumed to be 3 mm for all product materials.³⁰ The product position on the sheet metal was chosen based on maximum percentage of the material used for minimum scrap metal.

The total punch-die clearance is considered to be a significant parameter which has an effect on burr heights of the sheet metal, and it was assumed equal to 0.04 mm. The dimensions of piercing punches of sheet metals were assumed based on design requirements as indicated in Table 3. Four cutting geometry profiles of compound die piercing punches which were flat, chamfer, flat with concave hemisphere, and convex shaped were used, as shown in Figure 3 .

Table 3. Dimensions of compound die piercing punches.

Figure 3. 3D cross-section of flat, chamfer, flat with concave hemisphere and convex piercing punch.

The dimensions of blanking die (die block) are calculated using the following formulae³⁰

The details of the blanking die are shown in Table 4. The upper and lower plates are used to hold the piercing punches and blanking punch-piercing die. The thickness of punch holder can be obtained by applying the following formula³¹

$$T_{\mathrm{ph}}=0.75H\mathrm{for}\mathrm{unguided}\mathrm{punches}$$

(7)

Table 4. Dimensions of compound die parts for each sheet metal.

The details of both plates are shown in Table 4. The blanking punch-piercing die is used to cut the sheet metal during the blanking and piercing process. A blank holder (knockout) is employed to hold the sheet metal during the double cutting operation. The stripper plate is utilized for supporting the sheet metal during the blanking process. The backup plate is used to support the piercing punch holder plate. These parts are shown in Table 4. The thickness of the stripper plate can be calculated by the equation below³¹

The top bolster plate carries the upper parts of the compound die, and the bottom bolster plate carries the lower parts of the die. The plate thickness can be computed by equations (9) and (10)³²

The details of both parts are shown in Table 4.

Helical compression knockout and stripper springs are selected, and they have a circular and rectangular section with squared and ground end. The first group of springs is located between knockout and piercing punch holder plate. The second group is used between the stripper plate and lower holder plate. Two types of screws are utilized for connecting the different parts of the compound die. The number and dimensions of guide pillars, sleeve bushings, and shanks are selected for both compound die models based on die design requirements using available manufacturing data.

The assembly stage was achieved by connecting all die parts together of both models for AISI 1018 and AISI 202 sheets. The difference between each model is just in the dimensions, and the completed compound die can be seen in Figure 4 .

Figure 4. 3D compound die assembly for AISI 1018 sheet.

Modeling and analysis

In this section, the simulation of the blanking and piercing operations for AISI 1018 and AISI 202 sheets was carried out using compound die models for producing EGR plate. Several procedures were followed to complete the modeling and analysis process for obtaining burr height values of both sheet metals with different thicknesses and cutting shapes of piercing punches. The stages of numerical simulation using FEA are presented in the flow chart as shown in Figure 5 . The FEA was carried out using commercially available software ANSYS, version 17.2.

Figure 5. Numerical methodology of compound die with blanking and piercing process.

The compound die assembly geometry is simplified to reduce the analysis time and cost. Therefore, seven active parts of the die, including piercing punch, blanking die, blanking punch-piercing die, upper and lower holder plates, stripper plate, and knockout, were selected for simulation. The sheet metal properties of the EGR plate are shown in Table 1. The type and properties of the material for compound die parts were selected based on ANSYS workbench software database as shown in Table 5. The symmetrical option was implemented by dividing the simplified compound die to two equal parts to save time and cost.

Table 5. Material properties of compound die parts.

The manual connection between compound die parts was applied to obtain accurate and correct numerical results. In the analysis process, the manual contact method was applied on some parts of the die model as the other parts were already in contact condition at the geometrical stage. The contact options between the die components were divided into frictionless, bonded, and frictional (sliding friction) using faces and bodies. The automatic contact method of model parts could not be used because the ANSYS program cannot understand the nature of all types of contacts. The final step to complete the contact procedure is to select the spring details, including location, number, length, and stiffness.

The mesh determination is considered a vital stage that plays a significant role in the analysis process and results accuracy, especially when using explicit dynamics analysis. The mesh quality was improved using h-convergence method, average orthogonal quality, and skewness as indicated in Table 6. It is found that the average orthogonal quality values (0.86 and 0.76) for AISI 1018 and AISI 202 sheets, respectively, are considered very good compared with available published standards³³ of mesh quality as shown in Table 7. The skewness value (0.24) for both sheets is considered excellent compared with published data³³ as outlined in Table 8. The analysis time is dependent on the mesh size. When the element size is very small, the analysis process will take a very long time, which could run into weeks or months. Therefore, a decision was made to obtain a balance between the mesh size and outcome accuracy to save time and cost. The automatic method of mesh selection is applied on proposed models at element size of 2 mm. The sheet metal was meshed using body sizing option at element size 0.7 and 0.2 mm and edge sizing at a number of divisions of 3. The edge sizing option at element size 0.5 mm was implemented for blanking punch-piercing die, piercing punch, blanking die, stripper plate, and knockout. The total number of elements and nodes is increased in the cutting (shear) region because this area is exposed to high levels of deformation compared with other regions, while low density of mesh is applied to zones which are located after the cutting region.

Table 6. Average orthogonal quality and skewness.

Table 7. Average orthogonal quality mesh metrics spectrum.33

Table 8. Average skewness mesh metrics spectrum.33

The boundary conditions such as cutting speed, total analysis time of completed double cutting process, total cutting force, blank holder force, and fixed support were applied to compound die parts. Different speeds were applied to obtain the best cutting speed for a clean cutting edge of the product under minimum burr height formation. The cutting speeds (movements) were applied to upper holder plate, blanking die, piercing punches, and the knockout part. The blanking and piercing forces were located on three different faces, including upper holder plate and the two punches. The blank holder force was applied on the upper surface of the knockout. The fixed support option was selected on two faces involving the lower holder plate and the blanking punch-piercing die.

The values of different parameters which are used in implementing the simulation stage in ANSYS are presented in Table 9. These values are applied on the half part of the compound die model.

Table 9. Values of different parameters of ANSYS software.

Results

Simulation

The simulation results were obtained for the EGR plate using commercial ANSYS software. The final outcomes depended on directional deformations (burr heights). These burrs were measured at bottom edges of AISI 1018 and AISI 202 sheets for blanking and piercing operations. The cutting edges of both sheets were divided into equal sections to obtain burr height value at each section point, as shown in Figure 6 . The total summation of these points was used to obtain average burr height for double cutting process using different piercing punches.

Figure 6. Burr heights of AISI 1018 sheet (thickness: 2 mm) using chamfer punch at a cutting speed of 35 m/s.

Two samples of compound die, flat punch, both sheet metals with thickness 1 mm and cutting speeds including 50, 55, 60, 65, 70, and 90 m/s are selected here for presentation. These samples are used to compare the current burr heights with experimental data of Lahoti and Phafat.³⁴ It is assumed that the simulation cutting speed for this study is similar to the experimental cutting speed for comparison and validation purpose of proposed compound die models. The comparison process indicates that the burr values increase when using high cutting speeds and decrease when applying low cutting speeds, as shown in Figures 7 and 8 . The observed differences between the experimental and simulation results could be due to errors from experimental work and the iteration process.

Figure 7. Burr heights graph of AISI 1018 sheet with thickness 1 mm using various cutting speeds.

Figure 8. Burr heights graph of AISI 202 sheet with thickness 1 mm using various cutting speeds.

It was found that each punch gave different burr heights when using different materials and thicknesses, as shown in Figures 9 and 10 . These punches were made to travel a constant distance of 1 mm beyond the sheet metal to confirm completed cutting operation for measuring burr heights correctly and accurately.

Figure 9. Burr heights graph of AISI 1018 sheet with different thicknesses and punches.

Figure 10. Burr heights graph of AISI 202 sheet with different thicknesses and punches.

Two different model results have been selected for both sheet metals, and these represent the lowest burr values compared with other models of punches used. The average burr height was determined for each sheet metal and piercing punch. It was calculated based on burr values using various cutting velocities, including 30, 35, and 40 m/s. The current burr heights for AISI 1018 and AISI 202 sheets with different thicknesses, punches, and cutting speeds are compared with available published experimental data,³⁴ as shown in Figures 9 and 10 .

Optimization

In this study, various parameters were selected for optimizing the blanking and punching process using Taguchi method. These parameters are sheet metal thickness, product material, and cutting speed. Three levels for thickness and cutting speed were selected, and the combination between them was achieved using Taguchi method as indicated in Table 10. The optimum variables were predicted based on a statistical approach using regression analysis. This method is implemented using the commercial statistical software (Minitab, version 17) to obtain optimum equations of burr height estimation for each piercing punch and sheet metal.

Table 10. Parameters levels with combination for both sheet metals using Taguchi method.

The mathematical model is completed after inputting the data to the statistical parameters in the Minitab table. These parameters are responses (average burr height values) and continuous predictors including sheet metal thicknesses and cutting speeds. The minimum burr heights can be obtained using the burr height equations which were achieved using various sheet metal thicknesses such as 1, 1.5, and 2 mm and cutting speeds such as 30, 35, and 40 m/s, as outlined in Table 11.

Table 11. Optimum burr height equations for both sheet metals using various punches.

Discussion

The FEA using ANSYS software is adapted to obtain optimum compound die piercing punch shape using different parameters. These parameters are clearance, sheet metal thickness, product material, cutting speed, and blank holder force. More accurate outcomes were achieved based on suitable selection of die parts with their materials properties, symmetrical choice, boundary conditions, contact type between die parts, and mesh quality. The various deformation values (burr heights) for carbon steel AISI 1018 and stainless steel AISI 202 sheets were obtained using number of compound die models and selected variables. The optimum punch for each compound die model and sheet metal was selected based on the minimum burr height.

It is found that the minimum average burr heights of AISI 1018 and AISI 202 sheet occur when they are cut using the chamfer and convex piercing punches at cutting speeds of 35 and 30 m/s, respectively, and a thickness of 2 mm. It is seen that both punches represent the optimum results of the compound die models. The two punches provided better cutting quality of the EGR plate compared with other punches such as concave hemisphere and flat. The burr height values of both sheet metals when utilizing other tools are found to be close to the optimum tools as indicated in Figures 9 and 10 .

It is observed that the ductility of AISI 202 is lower than that of AISI 1018. This could result in the rate of deformation caused by the different punches on the materials to be different. This difference in deformation shows the results seen above in Figures 9 and 10 . The best tools are selected based on minimum burr height criterion, which is based on observed burr heights for both sheet metals using different piercing punches. These are regarded to be the optimum tools for cutting the AISI 1018 and AISI 202 sheets with thickness of 2 mm as they provided minimum average burr values at various cutting speeds including 35 and 30 m/s. The other reason for obtaining various burr values in this study is related to using different piercing punches.

It is found that the average of burr values for sheet metals with various thicknesses, punches, and cutting speeds are much lower when compared to the experimental data of Lahoti and Phafat,³⁴ as shown in Figures 9 and 10 . There is a significant difference between averages of burr height in this study and published data for AISI 1018 and AISI 202 sheets. It is probably because the previous authors used high cutting speeds to implement the single blanking operation. This is confirmed when using high cutting speeds including over 59 m/s of AISI 1018 and over 55 m/s of AISI 202 which both provided larger burr values when compared with data in the literature.

The other possible reason of the low burr values could be due to the differences in stiffness of the current compound die and previous blanking die. In addition, the proposed design method of current compound die models using the active die parts could be another reason of the large differences in burr heights of the product. It is clear that the proposed compound die models used in this study provided better cutting edges of the product and significantly lower burr heights in comparison with the experimental results.³⁴

A statistical methodology using Taguchi method and Minitab software was adapted to achieve the optimum parameters of blanking and piercing operations. The Taguchi method provided the various options of both sheet metal thickness and cutting speed. Regression analysis method using Minitab was applied to both sheet metals with various thicknesses and speeds to achieve different mathematical equations of predicted burr height for each piercing tool. The Minitab software automatically analyses the data of burr height, sheet metal thickness, and cutting speed to generate the burr height equations. It provided three mathematical equations based on different relations between the material thickness and cutting speed variables. The parameters combination includes three options which are individual variables, cross-correlation with separate individual variables, and different cross-correlation with separate individual variables. The optimum mathematical model was chosen based on the equation that provided minimum burr heights. The selected mathematical model represents the best option compared with other mathematical models, as it provides the lowest burr values.

Conclusion

The piercing punches are considered one of the main active compound die parts that play significant role in the cutting process of the sheet metal. This finite element investigation used commercially available ANSYS software and regression analysis (Minitab) to present the effect of different parameters on optimization of piercing tool edge geometry and double cutting process. These parameters are sheet metal type and thickness, blanking and piercing force, cutting speed and time, punch-die clearance, and blank holder force.

The optimization was achieved based on minimum burr heights of the EGR plate. The burr heights were maximum at 1-mm thickness of AISI 1018 and AISI 202 sheets, while they were minimum at 2-mm thickness of both sheet materials. The punch models developed here show that the burr heights are at a minimum when the sheet material is thicker and larger when the material is thinner. The chamfer and convex punches resulted in minimum burr heights as low as 0.034 mm for a typical sheet metal compared to 0.1 mm found in the literature.

Hence, the proposed model developed in this study provides a better outcome in relation to lower burr height. The final results indicated that the various models of the compound die have enabled the blanking and piercing task in a one step process. These models can be used to predict the minimum burr height and obtain better performance of the compound die in terms of no buckling of cutting tools. They can provide clean cutting surface of the products and implement the double cutting operation without failure.

It can be concluded that the proposed compound die models with their optimum piercing tools can be used in the stamping industry. This research has shown that the use of compound dies can lead to better product quality, thereby reducing production cost and improving product accuracy.

Appendix 1

Notation

a Opening die dimension (product length in mm)

A Die block dimension (length in mm)

b Opening die dimension (product width in mm)

B Die block dimension (width in mm)

c Constant

e Distance between edge of product and edge of blanking die (mm)

$F_C$  Cutting force (kN)

$F_S$  Stripping force (kN)

H Die block height (thickness in mm)

L Cut length (mm)

P Sum of perimeters of all punching and blanking faces (mm)

S_S Material shear strength (MPa)

t Sheet material thickness (mm)

T₁ Bottom plate thickness (mm)

T₂ Top plate thickness (mm)

T_ph Punch holder plate thickness (mm)

T_str Stripper plate thickness (mm)

T_PC  Total press capacity (kN)

T_PT  Total press tonnage (kN)

Acknowledgements

The authors thank the Ministry of Higher Education and Scientific Research, Republic of Iraq, for the scholarship support to W.S.

Declaration of conflicting interests
The author(s) declared following potential conflicts of interest with respect to the research, authorship, and/or publication of this article: W.S. is bonded to return to his university after his PhD studies. The remaining authors have no conflicting interests to declare except the obligation to UNSW.

Funding
The author(s) received no financial support for the research, authorship, and/or publication of this article.

ORCID iD
Sangarapillai Kanapathipillai https://orcid.org/0000-0003-1103-3978

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Designing A Punch And Die Cutoff Tool

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