Simulation of metal punching and trimming using minimal experimental characterization

This paper presents a validated finite element modeling approach for simulating shear cutting, needing minimal amount of experimental characterization. Only one uniaxial tensile test and force–displacement relationship from punching experiment are needed calibration, with maintained prediction accuracy compared to more experimentally demanding approaches. A key ingredient is the observation that Lode angle parameter close zero in fracture region, postulating strain only depends on stress triaxiality, free calibration parameter. The true stress–strain behavior provided inverse test, whereas model calibrated using test. verified different materials by comparing curves experiments not used calibration. error intrusion below 4%. validation made two setups. local residual stresses measured Focused Ion-Beam Digital Image Correlation (FIB-DIC). simulated values within bounds. Cut edge morphology plastic strains obtained nano-indentation mappings simulation results, showing decent agreement. For trimming, cut performance decreases at 17% cutting clearance while it over whole range punching. predicted hardness have mean absolute percentage 7.5%. Finally, effect size remeshing discussed quantified. characterization effort needed, enables an efficient optimization process industry.