Finite elements simulations of thin copper sheets blanking: Study of blanking parameters on sheared edge quality

Abstract The capabilities of finite elements codes allow now accurate simulations of blanking processes when appropriate materials modelling are used. Over the last decade, numerous numerical studies have focused on the influence of process parameters such as punch–die clearance, tools geometry and friction on blanking force and blank profile (sheared edge). The proposed study focuses on the finite elements simulations of a blanking process using a new viscoplastic model for the evolution of the flow stress coupled with a new damage model. The commercial finite elements code ABAQUS/Explicit has been chosen to simulate the blanking process. The finite elements predictions have been compared with experimental results. Then the finite elements simulations have been used to assess the influence of punch–die clearance as well as the influence of tool wear and friction on sheared edge quality.