A novel method to significantly decrease the die roll during fine-blanking process with verification by simulation and experiments

Abstract The die roll of fine-blanking parts is an important indicator when evaluating quality of parts. In this paper, the formation of die roll during the punching process is analyzed through the difference of the velocity of material between the die roll area and center area. At first, an assumption is made that every die roll is determined by the volume proportion of the part and waste area in the circular affected zone, and it is proved by simulation. In addition, the introduction of insertion block can prevent the fracture on the shearing surface without V-ring. In consideration of waste affect area and insertion block, a novel combined method is designed to decrease the die roll. It turns out that the height of die roll can be reduced by as much as 70% in both FEM simulation and actual experiment, which shows a great potential in fine-blanking industry.