19.11.

2018 R&D Update: Edge fracture in hole extrusion and flanging, Part II - The Fabricator

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R&D Update: Edge fracture in hole extrusion and

flanging, Part II
How shaving can reduce fracture in collar forming
STAMPING JOURNAL SEPTEMBER/OCTOBER 2018 (/PUBLICATION/SJ/SJ-SEPTEMBER-OCTOBER-2018)
OCTOBER 11, 2018
BY: ADVAITH NARAYANAN (/AUTHOR/ADVAITH-NARAYANAN), DAVID DIAZ INFANTE (/AUTHOR/DAVID-DIAZ-INFANTE),
TAYLAN ALTAN, PH.D. (/AUTHOR/TAYLAN-ALTAN)

Editor’s Note: Part I appeared in the July/August 2018 issue and discussed the effect
of process variables in blanking (piercing).
Two-stage blanking, also known as shaving,
can be used to improve edge stretchability.
With this method, the operator blanks an initial
hole of a smaller diameter than the desired
hole. Then a larger hole is blanked with the
desired dimensions before collar forming.

Shaving has been shown in research and

practical experience to reduce edge fracture in
collar forming (see Figure 1). Variables that
affect this operation are the punch/die
clearances (u1, u2) and the blanking offset (z).

Effect of Strain (https://static.thefabricator.com/a/r-d-update-edge-fracture-in-

Hardening/Hardness hole-extrusion-and-flanging-part-ii-1539206574.jpg?
size=1000x1000)
In blanking and shearing operations, very high
strains develop near the sheared edge after
cutting. This means the material is significantly strain-hardened, leaving little room for additional stretching
during subsequent operations, especially when blanking advanced high-strength steels (AHSS).

Recent studies conducted at Technical University of Munich (TUM) concluded that hardness near the sheared
edge, or shear-affected zone (see Figure 2), is directly correlated to edge fracture during collar forming.
Researchers observed that the shaving leads to lower strain hardening than in single-stage blanking.

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19.11.2018 R&D Update: Edge fracture in hole extrusion and flanging, Part II - The Fabricator

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To investigate how local hardening in blanking affects edge fracture in collar forming, researchers evaluated the
edge stretchability achieved for different blanking clearances (u1, u2) and cutting offsets (z) using the hole
expansion ratio (λ). A higher λ value indicates better edge stretchability in collar forming. λ is determined by:

λ (in %) = (D-d x 100)÷ d

Where:

D = Diameter of punch during collar forming

d = Diameter of blanked hole before collar forming

At TUM, researchers performed collar forming tests on CP-W 800 cold-rolled steel, 4 millimeters thick. The first
series of tests used a 50-mm-diameter hole, blanked at various punch-die clearances between 5 and 30 percent
of the sheet thickness. The maximum hole expansion ratio (λ) that could be achieved was about 5 percent. As a
comparison, collar forming using a machined (milled) hole could yield a hole expansion ratio of nearly 90
percent.

Additional tests used punch/die clearances of 10 and 15 percent in two consecutive shaving operations
respectively. The second operation used cutting offset values (z) of 2, 3, and 4 mm. The results indicated that
the selected shaving-tool geometries could produce a hole expansion ratio (λ) up to 40 percent.

These results clearly show that, for certain AHSS, shaving may be a useful technique to reduce or postpone the
probability of edge fracture in collar forming. Obviously, additional studies may be needed to investigate the
quantitative selection of shaving conditions for other AHSS material and thicknesses.

(https://static.thefabricator.com/a/r-d-update-edge-fracture-in-hole-extrusion-and-flanging-part-ii-
1539262718.jpg?size=1000x1000)
Figure 1
Shaving, or two-stage blanking, has been shown to reduce edge fracture in collar forming.

Estimating Tool Dimensions to Reduce Edge Fracture

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19.11.2018 R&D Update: Edge fracture in hole extrusion and flanging, Part II - The Fabricator

To replicate the experimental results obtained at TUM, researchers at The Ohio State University’s Center for
Precision Forming conducted finite element (FE) simulations on different AHSS of varying thicknesses. Their
goal was to estimate the tool dimensions for shaving that would reduce edge fracture in collar forming.

Figure 3 shows the schematic of the collar forming operation that underwent FE simulations. The distribution of
strains generated in single-stage blanking and shaving, using the FE method, is shown in Figure 4. The strain
values, obtained as a function of distance from the blanked edge, are shown in Figures 5 and 6 at two different
locations in the thickness of the blank. These results also show, as did the studies conducted at TUM, that
shaving leads to a relatively softer blanked edge and reduces the probability of edge fracture in a collar
extrusion.

The strains, estimated in collar forming with and without a secondary shaving operation, are shown in Figure 7.
The strains at the edge of the formed collar obtained in both cases show that shaving reduces the strains and
consequently the chances of potential fracture.

It is necessary to predict at what edge strain or edge thinning level that fracture may occur. Studies are in
progress to determine a relationship among strain hardening, edge thinning, and the probability of fracture for
different AHSS and thicknesses.

References

I. Pätzold, F. Dittmann, M. Feistle, R. Golle, P. Haefele, H. Hoffmann, and W. Volk, “Influence of shear cutting
parameters on the fatigue behavior of a dual-phase steel,” Journal of Physics: Conference Series, Vol. 896, No.
1 (2017), p. 012107.

M. Feistle, I. Pätzold, R. Golle, W. Volk, A. Frehn and R. Ilskens, “Maximizing the expansion ratio through multi-
stage cutting process during collar-forming,” 37th International Deep Drawing Research Group Conference,
Waterloo, Canada, 2018.

I. Pätzold, M. Feistle, R. Golle, W. Volk, A. Frehn and R. Ilskens, “Determination of the minimum possible
damage due to shear cutting using a multi-stage shear cutting process,” 37th International Deep Drawing
Research Group Conference, Waterloo, Canada, 2018.

 Slide Show | 8 Images

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Contact via email (mailto:https://cpf.osu.edu)

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