from the conferences organized by TANGER Ltd.
Shear cutting operations, such as blanking, are critical in forming technology but often oversimplified in FE simulations, reducing predictive accuracy for cut edge quality. This study evaluates three failure modelling approaches for a FE model of DC04: the modified porous Gurson model and the Johnson-Cook model with element deletion and mesh separation. Experimental validation of the cutting characteristics rollover, burnish, fracture and burr showed that the JC model with mesh separation produced the most accurate results, with up to 99.86 % certainty. Based on this validated model, a factorial parameter study identified punch radius and sheet thickness as the dominant factors influencing burr height, while die radius and clearance exhibited minor effects. Numerical investigations of alternative blanking processes demonstrated that fine-blanking, counter-blanking and notch-blanking produced burr-free cuts, while hollow-blanking and two-stage blanking showed a less strong influence. These results confirm the capability of validated FE simulations for process optimisation. The investigation confirmed that the accuracy of shear cutting simulations strongly depends on the implemented failure model. Among the tested approaches, the Johnson-Cook model combined with mesh separation produced the most accurate predictions of rollover, burnish, fracture and burr for DC04, compared to experimental blanking results. This validated modelling framework enabled a systematic parameter analysis, demonstrating that burr height is primarily governed by punch radius and sheet thickness, while die radius and clearance exert only secondary effects. Furthermore, the comparative assessment of process variants established that fine-blanking, counter-blanking and notch-blanking substantially suppress burr formation. These findings highlight the potential of physically motivated and experimentally validated FE models to replace oversimplified Boolean operations, thereby enabling the predictive simulation of shear cutting.
Keywords: DC04, shear cutting, numerical simulation, effect analysis, fine cutting© This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.