LIFE ESTIMATION OF HSS HOLE PUNCH TOOL IN A FINE BLANKING OPERATION

Abstract

Blanking or piercing 0is one of the most commonly used sheet metal manufacturing processes in the industry. Having a good understanding of the fundamentals and science behind this high deformation shearing process can help to improve the tool life. The HSS Punch tool is used to punch the 12mm thickness of sheet metal (suspension arm) to make a fine blanking component. The punch tool is shear the 12mm thickness of sheet metal the effect of bur formation, Punch-die clearance, tool tip geometry causes tool get failure. The interaction between punch, stripper plate and sheet metal of 12mm thickness is first studied experimentally by using different geometry of Punch tools, since a fundamental understanding of the behaviour of the components at different loads at high speeds. By the experimental results select the best performed tool and that punch tool material is analysed by conducting material testing by reference of its specification they are chemical analysis, hardness test, thermal and micro testing. The stress distribution is determined by using Ansys simulation for both punch tool and the sheet material (12mm thickness suspension arm). The life estimation of HSS flat punch tool is calculated theoretically and compares it with the ansys simulation results and determines the safety factor of the tool.