Abstract:

The metal stamping process is nowadays one of the most common processes used in industry. Millions of parts are produced by this method every day. Every single advance in this process represents a big step forward in improvement of the process. The metal stamping process is completed in short period of time, with extremely high forces resulting in material deformation elastic and plastic, hardening of the material, micro cracks, macro cracks, generation of heat due to friction. As a result, many problems can occur, such as: wrinkling, sub thicknesses located, among other fractures. When one of these failures occur, it is important to make a diagnosis of the cause of the problem. The FEM (Finite Element Method) simulation can help to predict and solve those problems.
The results given by this method are used to change some inputs of the process can be changed, like blank holder force, geometry of the punches and dies.
In this work a study of the evolution of a progressive die tool was carried out, using finite element software (LS-DYNA). The aim of this study is to make a comparison between the parts obtained by the progressive die, and the results obtained by LS-DYN.
The tool in study has experienced three major developments, having been essentially changed the geometry of punches and dies.
It was made a comparison of the thickness obtained in the actual process, with the thickness obtained in the simulation. The results are very similar to the actual process, with a maximum error of 3,23%.

Keywords:

metal stamping, progressive die tool, finite element method.