Blanking die design and stress analysis using FEM

This project investigates the design of a blanking die and analyzes the stresses generated during sheet metal cutting using theoretical and numerical approaches. The blanking die was designed using standard mathematical equations, and the cutting process was simulated using the finite element method (ANSYS Explicit Dynamics) to evaluate stresses on the blanking punch. The aim was to develop an optimized die model that ensures high cutting quality with minimal burr formation and reduced stress concentration at the cutting edges, thereby extending die life and lowering manufacturing costs. The simulation evaluated three sheet materials—AISI 1006 steel, AL6061-T6 aluminum alloy, and tungsten—by determining the equivalent (von Mises), maximum shear, and normal stresses at the cutting edge. Results showed the highest equivalent stress in tungsten (1713.3 MPa), followed by AISI 1006 steel (1360.2 MPa) and AL6061-T6 (572.16 MPa), confirming that material type and cutting speed significantly affect the induced stresses and deformation, with an optimal cutting speed existing for each material. The study provides a validated die design and stress-prediction procedure to guide material and parameter selection for improved die performance. Future work is recommended to extend this approach to compound and combination dies for double cutting or combined cutting-and-forming operations.