The project, which have been created within the framework study of engineering branch N2301-2, submit technology project of presswork – car reinforcement from material H 220 P and concept of multi-tool set design for pressing operations 1, 2 and 3. Technology process was designed in six operations, based on literary study of blanking and drawing technology. Multi-tool set is design in according with transfer press Müller Weingarten 1250T-1, which was chosen on the basis of advantageousness calculation. Project includes technical and economical evaluation of elaborated technology whit two other variants of production.

Academic thesis, drawn up within the framework of engineering studies, presents a proposal optimal production of garage door lock striker. The part is manufactured from steel sheet S275JR of 1.5 mm thickness. By the analysis of its possible methods of production, with regard to the required annual series of 500,000 pieces, was chosen technology of manufacturing the part in the compound tool by blanking and bending processes. For these technologies was designed solution of the compound tool and automatic production line with the eccentric crank press SMERAL S160, where is the compound tool fixed. The measure of financial performance of manufacturing the part is economical assessing. In the current state is investment return in the production of 179,186 pieces of the parts.

Increasing effectiveness of semi-tightening tips production on the Swissstyle lathes. Analysis of current status. Design of areas for improvement. Proposed measures in the form of changes in cutting conditions, changes in geometry of tool, or an alternative solution to the current situation. Technical and economic evaluation of the proposed measures.

When dealing with the separation of materials, the metal shearing process such as punching, is widely used in theindustry due to its time efficient manner. There is however, a need to better understand the process in order toimprove quality of the final product. Working with numerical simulations of themetal shearing process, there aretwo major difficulties. One being the extremely large deformation, the other being material failure. The combinationof these two makes numerical modeling challenging and is the reason for this study.The problem was divided in to two main parts, one where material modeling was studied, the other part focusedon numerical modeling and experiments of the punching process. A material model considering both plasticityandmaterial failure was created for a boron steel material. Plasticity behavior of thematerial was modeled with anelasto-plastic model and a calibratedModifiedMohr-Coulomb (MMC) failure criterion to model the material failure.The resultingMMC-model agreed well with the experiments.Punching experiments with varying clearances were performed on the boron steel. Punch forces and displacementswere continuously sampled throughout the process, and after the punching experiments were finished the punchededge profiles were studied. The multiphysics simulation software LS-DYNA was then utilized, and three dimensionalsimulations of the punching process using the Smoothed Particle Galerkin (SPG)method were performed.Results from the SPG-simulation corresponded very well with the results from punching experiments, and it can beconcluded that the model was able to capture the material behavior of the sheet in a highly detailed level. When thepunched edge profiles from the simulations were compared to the experiments, there was an almost exact match forall the cases studied. The force-displacement behavior of the punch from simulations was in great consistency withexperimental results as well.Itwas also concluded that the combination of a stress state dependent failure criterion together with the SPG-methodshows significant possibilities to cope with three dimensional problems where large deformations in combinationwith difficultmaterial failure occurs. This study focuses on the punching process, but the generality of this novelmodeling technique can be applied to many industrial cases and is a step towards a better and more reliablemodeling of failure in combination with extremely large deformation.

The present Master´s thesis deals with the concept of press drive of Blanking press LKDS 800 used for blanking in automatic blanking line. The first part of the thesis is dedicated to the individual arrangements of press drives and servo press drives and to the description of main components. The second part of this thesis deals with the structural design of the drive. Based on the computation of the crank mechanism, several design solutions were suggested. From these solutions, the option with the lowest drive height is selected. This option, offers the computation of the main drive, flywheel, spur gearing and clutch/brake combination. This computation is followed by computations of individual construction nodes, which include a design and dimensioning of the individual joggles, shafts and bearings. The drawing of the press and clutch shaft assemblies with a list of items are also included.

Les constructeurs automobiles utilisent des aciers auto-trempant à haute résistance au bore manganèse (22MnB5) pour des questions de sécurité et environnementale. La mise en forme à chaud de tôles constituées de cet acier impose aux outillages des contraintes mécaniques sévères et un échauffement intense. L'intégration d'une fonction de cisaillage sous presse à suivre permet de répondre à des problématiques rentabilité de production, mais les lames sont confrontées à des problèmes similaires de durabilité. L'objectif de cette thèse est de comprendre la dégradation des outils de cisaillage à chaud afin de proposer des guides de choix de matériaux d'outil (X38CrMoV5-3 ou X70CrMoV5-2) et de paramètres du procédé. Cela requiert l'estimation des sollicitations mécaniques et thermiques dans la partie active de l'outil. La méthodologie développée passe par quatre étapes : une recherche bibliographique, des essais de cisaillage à chaud sur un module spécifique du pilote MEFISTO de l'ICA, le développement d'un modèle thermomécanique éléments finis de l'opération et des analyses des microstructures. Un état de l'art portant sur la définition de l'opération de découpage de tôles, sur les propriétés physiques et mécaniques du matériau de tôle et des lames, le comportement à l'interface tôle/outil et sur les techniques permettant de simuler le découpage a été proposé. Des essais sur le module de découpage ont permis d'accéder à des résultats d'effort et des observations des endommagements des lames de cisaillage. Ces informations sont utilisées pour valider le modèle de calcul éléments finis. Ce modèle montre que les contraintes mécaniques sont locales, intenses et se déplacent dans l'arête de coupe. De plus, l'échauffement de l'outil engendre une température de surface proche des températures de revenu des matériaux d'outil. La comparaison des résultats de simulation numérique et de l'étude expérimentale permettent de comprendre le lien entre les dégradations observées et les sollicitations thermomécaniques. / Car manufacturers are building using a self-hardening high strength boron steel (22MnB5) for safety and environmental concerns. But the shaping of sheets made of these kind of steel imposes on tools severe mechanical stresses and strong thermal transfer. The integration of a blanking function in transfer presses is a response to reach high profitability, but blades are subjected to the same durability problems. The aim of this thesis is to understand how hot blanking tools are wearing in order to give to manufacturers tool material guidelines (X38CrMoV5-3 or X70CrMoV5-2) and process parameters guidelines. To do so, an estimation of mechanical stresses and thermal solicitation is required. The methodology is based on four steps: literature search, hot blanking trials on a specific module of ICA laboratory industrial pilot MEFISTO, finite element simulations of the operation, and microstructural analysis. The state of art is focused on the description of the operation, the physical and mechanical properties of the blank material and tools materials, the blank/tool interface behavior, and the techniques used simulate the hot blanking process. Trials on the hot blanking module provided blanking force and observations of worn blades. These informations are needed to validate the finite element model. This model shows that mechanical stresses are local, intense and slides in the blade cutting edge. Moreover, the blade heating generates a surface temperature close to tool steel tempering temperature. Experimental results compared to numerical ones allow to understand the link between thermo-mechanical stresses and how the damage occurs.

La qualité des pièces découpées pour les industries électroniques et micromécaniques est appréciée via trois critères principaux : le niveau de bavure, l’aspect du bord découpé et la précision dimensionnelle. Or, l’étude de la qualité des pièces découpées ne peut se faire sans une compréhension de l’usure des poinçons. Ainsi, des méthodes de mesure en continu et in situ de l’usure ont été mises au point et validées, soit l’activation superficielle et la mesure par double réplique. Ainsi, il a été possible de suivre l’influence d’un certain nombre de paramètres du procédé sur l’évolution de l’usure lors du découpage. Par ailleurs, nous avons mis au point une méthode de quantification de la bavure sur la totalité du contour découpé. Il a ainsi été possible d’étudier l’évolution de la bavure au cours de la découpe. L’aspect des bords découpés a été examiné grâce à des relevés topographiques permettant le suivi de son évolution. Ainsi, une corrélation entre la cinétique d’usure des poinçons et l’apparition de la bavure a été établi. De plus, une simulation expérimentale de l’usure des poinçons a été entreprise. Un dispositif expérimental de tribométrie a été conçu et installé sur la ligne de presse, simulant les conditions de frottement d’un poinçon sur une tôle. Il a permis d’évaluer l’abrasivité des tôlesminces vis-à-vis des poinçons. Par ailleurs, une modélisation numérique de l'opération de découpage par éléments finis a été entreprise, permettant d’approcher le profil d’usure d’un poinçon de géométrie cylindrique. Et par conséquent la possibilité de prédire son évolution en fonction du nombre de pièces découpées devient accessible en fonction des paramètres du procédé / The blanked parts quality for electronic and amicromechanical industry is assessed using threemain criterions: the burr amount, the appearance ofthe cut edge and dimensional accuracy. However, thestudy of the quality of the blanked pieces can not bedone without an understanding of the punches wear.Thus, methods for continuous and in-situ wearmeasurements have been developed and validated:Thin Layer Activation and measurement by doublereplica. Thus, it was possible to follow the influenceof process parameters on the wear evolution duringblanking.In addition, we have developed a method forquantifying the burr on the entire blanked contour. Itwas thus possible to study the evolution of the burrduring blanking. The appearance of the cut edges wasexamined by means of topographic survey for monitoringits evolution. Thus, a correlation between the kinetics ofpunches wear and the appearance of the burr has beenestablished. In addition, an experimental simulation ofpunches wear was undertaken. An experimentaltribometry was designed and installed on the press line,simulating the conditions of friction of a punch on onesheet. It evaluated the abrasiveness of thin sheets againstthe punches.Additionally, a numerical modelling of blanking wasundertaken to approach the wear profile of a punch ofcylindrical geometry. And therefore the ability to predictits evolution contingent on the number of blanked pieces becomes available depending on process parameters