Browse > Article

A study on the prediction of punch wear level through analysis of piercing load of aluminum  

Yong-Jun Jeon (Mold & Metal Forming R&D Department, Korea Institute of Industrial Technology)
Publication Information
Design & Manufacturing / v.16, no.4, 2022 , pp. 46-51 More about this Journal
Abstract
The piercing process of creating holes in sheet metals for mechanical fastening generates high shear force. Real-time monitoring technology could predict tool damage and product defects due to this severe condition, but there are few applications for piercing high-strength aluminum. In this study, we analyzed the load signal to predict the punch's wear level during the process with a piezoelectric sensor installed piercing tool. Experiments were conducted on Al6061 T6 with a thickness of 3.0 mm using piercing punches whose edge angle was controlled by reflecting the wear level. The piercing load increases proportionally with the level of tool wear. For example, the maximum piercing load of the wear-shaped punch with the tip angle controlled at 6 degrees increased by 14% compared to the normal-shaped punch under the typical clearance of 6.7% of the aluminum piercing tool. In addition, the tool wear level increased compression during the down-stroke, which is caused by lateral force due to the decrease in the diameter of pierced holes. Our study showed the predictability of the wear level of punches through the recognition of changes in characteristic elements of the load signal during the piercing process.
Keywords
Al6061; Load sensor signal; Piercing; Punch shape; Punch wear;
Citations & Related Records
연도 인용수 순위
  • Reference
1 M. Li, "An experimental investing on cut surface and burr in trimming aluminum autobody sheet", Int. J. Mech. Sci, Vol. 32, No. 5, pp. 889~906, 2000.    DOI
2 S. Golovshchenko, N. Wang, Q. Le, "Trimming and sheared edge stretchability of automotive 6xxx aluminum alloys", J. Mater. Process. Technol., Vol. 264, pp. 64~75, 2019.    DOI
3 H. V. Ravindra, Y. G. Srinivasa and R. Krishnamurthy, "Acoustic emission for tool condition monitoring in metal cutting", Wear, Vol. 212, No. 1, pp. 87~84, 1997. 
4 W. Rmili, A. Ouahabi, R. Serra, R. Leroy, "An automatic system based on vibratory analysis for cutting tool wear monitoring", Measurement, Vol. 77, pp. 117~123, 2016.    DOI
5 W. H. Hsieh, M. C. Lu, "Application of backpropagation neural network for spindle vibration-based tool wear monitoring in micro-milling", Int. J. Adv. Manuf. Technol, Vol. 61, pp. 53~61, 2012.    DOI
6 H. Chelladurai, V. K. Jain and N. S. Vyas, "Development of a cutting tool condition monitoring system for high speed turning operation by vibration and strain analysis", Int. J. Adv. Manuf. Technol, Vol. 37, pp. 471~485, 2007.    DOI
7 X. Li, A. M. Bassiuny, "Transient dynamical analysis of strain signals in sheet metal stamping processes", Int. J. Mach. Tool. Manu, Vol. 48, pp. 576~588, 2008.    DOI
8 J. Stahlmann, M. Brenneis, "Understanding and improvement of industrial production how technology paves the way for productivity", New Development in Forging Technology, Vol. 2017, pp. 109~117, 2017. 
9 S. Y. Kim, A. Ebina, A. Sano, S. Kubota, "Monitoring of process and tool status in forging process by using bolt type piezo-sensor", Procedia Manufacturing, Vol. 15, pp. 542~549, 2018.    DOI
10 R. Hambli, "Blanking tool wear modeling using the finite element method", Int. J. Mach. Tools Manuf., Vol. 41, pp. 1815~1829, 2001.    DOI
11 R. Shivpuri, S. Singh, K. Agarwal, C. Liu, "Energy release rate based approach for the wear of punches in precision blanking of high strength steel", CIRP Annals, Vol. 60, pp. 307~310, 2011.    DOI
12 S. Golovshchenko, "Analysis of Trimming of Aluminum Closure Panels", JMEP, Vol. 16, Vo. 2, pp. 213~219, 2007.   DOI