Project in the Field of Research
Tool life increase of fine blanking punches by means of deep rolling (Aktifest)
Wear of the tooling active elements plays an important role in the sheet metal separation. The wear of the fine blanking punches should be minimized in order to ensure a high workpiece quality over the service life of the tool. Apart from tool coatings that can reduce the tool wear due to a lower friction mechanical surface treatment processes are also suitable for a significant reduction of the tool wear. Deep rolling is a process which can be used for a targeted modification of the surface layer state of fine blanking punches. The modification of the surface layer entails smoothening of the surface asperities, strain hardening and induction of compressive residual stresses.
The aim of the research project is an investigation of the tool life increase of fine blanking punches made of hardened tool materials due to a defined modification of the surface layer state by means of deep rolling. In the scope of the project an experimental sensitivity analysis is performed in order to identify the main influence factors and develop a description model. Additionally, numerical simulations on the basis of Finite Element Method are performed and validated by means of the experimental data. Numerical data provides information with regard to the stress distribution in the surface layer and its correlation with the residual stresses as well as surface layer properties of a deep rolled punch. Finally, a wear test of the deep rolled punches under industrial conditions is performed. The result of the research is a basic understanding of deep rolling of fine blanking punches made of hardened tool steels.
Project partners thank the Federal Minitstry for Economic Affairs and Energy for funding the research project Tool life increase of fine blanking punches by means of deep rolling in the scope of the funding initiative Central Innovation Program for SME.
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