Research On The Ultrasonic Vibration Assisted Fine Blanking And Process Optimization

Ultrasonic vibration assisted plastic forming technology is an advanced processing technology of metal materials.After decades of research and development,ultrasonic vibration has been widely used in the metal forming process,such as deep drawing,extrusion,upsetting and rolling process,ultrasonic vibration can improve the metal processing conditions to promote the forming quality of the parts.Fine blanking process can get bigger smooth cutting surface,higher precision of shape and position,surface roughness parts which is no need to process two times with low cost and high efficiency.The metal deformation resistance,metal flow and the state of materials stress and strain can affect parts quality and the service life of mould.If the ultrasonic vibration plastic processing can be combined with the fine blanking processing,which is used to change the materials forming force,metal flow and the state of materials stress and strain to improve the parts quallity and the service life of mould,there is great significance to promote the theoretical research,technology development and application of fine blanking,and reducing consumption of green manufacturing.In this paper,a finite element model using Deform-2D was created to investigate the ultrasonic vibration assisted fine blanking process,the model is used to simulate the conventional fine blanking process and ultrasonic vibration assisted fine blanking process.The plastic deformation process in conventional fine blanking and ultrasonic vibration assisted fine blankingprocess is analyzed and compared to analyze the velocity field,mean stress field and effective strain field during fine blanking process.With the valid finite element model,the forming force,metal flow and mean stress were analyzed,the crack and roll-over forming mechanism of the ultrasonic vibration assisted fine blanking process were revealed.Influence of fine blanking process parameters such as clearance,mould radius,blank holder force and counterpunch force were analysed in conventional fine blanking process and ultrasonic vinration assisted fine blanking process.According to the finite element model,ultrasonic vibratiom assisted fine blanking mould was designed.According to the existing experimental conditions,we finished conventional fine blanking process and ultrasonic vinration assisted fine blanking process experiment in different blank holder force and counterpunch force.The comparison between experiment results and finite element results revealed the mechanism in ultrasonic vibration assisted fine blanking process,and verified the accuracy of the model..