Numerical Simulation and Experimental Verification of the Blanking Process of Medium-Thick Aluminum Alloy Plate

In the blanking process of medium-thick aluminum alloy plate, the forming quality of the cutting surfaces is hard to meet the requirement. According to the sheet thickness, material, and geometry of the parts, the corresponding finite element mold was established, and the Deform-3D was used to simulate the blanking process of medium-thick aluminum alloy plate. The effect of blanking clearance and blanking speed on the cutting surface quality was studied. The results indicated that the increased blanking speed is beneficial to the acceleration of the shear deformation and fracture process of blanking material. As the blanking clearance decreases, the burr and tear at the edge of the blanking material are reduced. In addition, the properly applied blank holder force can prevent the transverse flow of the material in the shear zone. Based on the theoretical simulation of the material forming defects, the process parameters were optimized, the workpiece forming accuracy was improved, and the numerical simulation was verified by experimental experiment.