Design of experiment based analysis for sheet metal blanking processes optimisation

The blanking of metal parts for electronic components is subjected to a variety of process parameters. In this paper, an experimental investigation into the blanking process was carried out using tools with four different wear states and four different clearances. The aim was to study the effects of the interaction between the clearance, the wear state of the tool and the sheet metal thickness on the evolution of the blanking force and the geometry of the sheared profile. Designed experiments are an efficient and cost-effective way to model and analyse the relationships that describe process variations. The results of the proposed experimental investigation show the strong dependence between the geometrical quality of the blanked part and the magnitude of the force applied on the tool as well as the variations in the process factors.