Numerical and experimental investigation of the discontinuous dot indenter in the fine-blanking process

The fine-blanking process has been widely applied in industries to produce clean-cut surface parts. The V-ring indenter blank holder, which is an essential part of the fine-blanking tool, is notably important in increasing the cutting surface quality of blanked parts. Because the V-ring indenter is difficult to manufacture, it is difficult to ensure the machining accuracy, and the cost is notably high. In this study, a new discontinuous dot indenter blank holder is. presented. The discontinuous dot indenter blank holder can improve the quality of the fine-blanked surface, which is identical to that of the V-ring indenter, but the manufacture process is notably easy, and the cost is notably low. The hydrostatic stress, material flow and quality of the fine-blanked surface in the fine-blanking process were analyzed to reveal the discontinuous dot indenter mechanism. To obtain a larger burnished zone, the finite-element (FE) simulation and ANOVA technique were applied to optimize the discontinuous dot indenter parameters, i.e., dot diameters, fillet radius, distributions, positions and heights. Next, these optimal parameters were applied to fine-blank a spur gear, and the experiment results have a good agreement with the FE simulation results. Moreover, the results also indicate that the discontinuous dot indenter can be used in the fine-blanking process to obtain almost full clean-cut surface parts. (C) 2016 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.