Numerical prediction of resulting rollover shapes and sheared edges after blanking process

Over the years, the simulation of manufacturing processes has introduced several numerical challenges for researchers in computational mechanics. In particular, the numerical modeling of sheet metal blanking process involves different numerical issues that must be carefully treated: a large and highly localized deformation in the shearing zone prior to fracture, complex contact interactions between the tools and the
metallic sheet and finally, the ductile failure phenomenon. Despite that this process is one of the most
widely used cutting techniques for mass production, the process parameters are normally set by empirical evidence due to the physical complexity resulting from the extreme amount of shearing involved. In addition, the strain-rate dependent behavior of the material must be taken into account due to high punch velocities encountered in practice. Thus, an accurate numerical tool is extremely desirable to optimize the setting parameters of this technique and will lead to a better understanding of the process.