Dynamic Die Supply: Engineering Innovations for Edge Splitting Controlling

The widespread adoption of advanced high-strength steel and ultrahigh-strength steel (UHSS) in the automotive industry presents new challenges in sheet metal production, particularly in controlling edge splitting during shearing operations. These materials offer significant advantages, including reduced weight, improved fuel economy, and enhanced crashworthiness, but their use requires careful consideration of manufacturing processes.

Shearing operations such as blanking, piercing, and trimming are common in the production of sheet metal parts. However, the sheared surfaces are often subject to edge stretching during subsequent stamping and assembly processes, leading to edge splitting and reduced part quality.

Research on material behavior in traditional hole expansion tests has provided valuable insights into the factors influencing edge splitting. Empirical formulas have been developed to predict the hole expansion ratio (HER) for various alloys and thicknesses, highlighting the challenges posed by sheared edges compared to reamed holes.

The lower HER for punched holes, attributed to significant plastic deformation and crack propagation during cutting, underscores the need for precise control over shearing processes to minimize edge splitting. The size of the burnish zone, which dictates the level of plastic deformation, plays a crucial role in determining the susceptibility of sheared edges to splitting.

Click here to learn more about Dynamic Die Supply’s products.

Article with all rights reserved, courtesy of thefabricator.com

Photo with all rights reserved, courtesy of depositphotos.com