Finite element analysis of rotary blanking: Effects of punch geometries on cutting area and stress distribution

It is essential to develop efficient and cost-effective production methods to achieve or maintain international competitiveness. An innovative production method, such as rotary blanking, enables manufacturers to both reduce expenses and economize production time. However, there are not enough numerical analyses for this process. In this paper, numerical simulations of rotary blanking were performed. After comparing the cutting planes generated by conventional and rotary blanking experimental tests, the cutting areas of two punch geometries were analyzed. The influence of punch geometry on part quality was then investigated through simulations. The procedure for die stress analysis was established and stress distributions of the worksheet and the tools were analyzed.