An Experimental Investigation On Cut Surface And Burr Height In The Trimming Process Of AA6016-T4

In recent years,emission reduction and energy saving has become a hot topic,especially in the automobile area which deeply relies on the energy.As the increasingly request of the light weighting and security in automobile,the material AA6016-T4 which shows the good quality both in strength and weight is warmly welcomed by automobile industry.However,compared with the wide use of steel plate,the relevant process of AA6016-T4 needs a set of standards to guide the production.Based on the above situation,this paper designs an experimental investigation on cut surface and burr height in the trimming process of AA6016-T4,which aimed to research the relationship between the cut surface and the cutting parameters which include the cutting angle,the cutting clearance and the blade edge radius.The cutting clearance is defined as the percentage of the blank thickness and is controlled by thin steels which is mounted between the punch and punch plate.The cutting angle is controlled by a part which is mounted at the die and the die.Then four kinds of fracture criterion were researched which include Rice-Tracey and Oyane,Brozzo,McClintock.And they were compared in order to choose the most suitable fracture criterion.Finally,the simulation results were compared with the experiment and found that the McClintock is the closest one to the industrial situation.The paper get a few kinds of conclusions after the research of the trimming section and the analysis of the simulation results.1)The burnish depth ratio and the burr height both increase as the blade edge radius increases.The relationship between the burr height and blade edge radius is related with the cutting angle and cutting clearance as well as the relationship between the burnish depth ratio and the blade edge radius.The trimming section is highly affected by the blade edge radius under certain kind of cutting clearance and cutting angle.2)The burnish depth ratio increases and the burr height decreases as the cutting angle increases.The burr height changes significantly with large blade edge radius and small cutting clearance or with small large blade edge and large cutting clearance.The cut surface become uneven when the cutting angle is too large.3)The cutting clearance affects the stress and strain state between the punch and die which makes the initial bending moment of the sheet material different.As a result,the final tensile stress which will finally affects the fracture process and fracture mode is different.The burr height increases and the burnish depth ratio decreases as the cutting clearance increases.The burr height is highly affected by cutting clearance when cutting angle is small and the burnish depth ratio changes more obviously when the cutting angle is large.4)Four kinds of fracture criterion were compared and researched which include Rice-Tracy criterion,Oyane criterion,Brozzo criterion and McClintock criterion.Then the trimming process is simulated by Abaqus and finally the McClintock fracture criterion is proved to be the most suitable fracture criterion in simulation.Then the McClintock is used to simulate under different kinds of parameters to find that the simulation and experimental results are close to each other and the simulation can be used to indicate the real industrial.