Predictive Optimization Framework for Die-Punch Clearance in Copper Sheet Metal Blanking to Control Burr Formation

The blanking process is widely used in sheet metal industries for fabricating components. However, the global market for sheet metal production is highly competitive. In small-scale industries, predicting the optimal clearance between the punch and die to achieve high-quality results is challenging due to the lack of skilled operators and the high cost of affordable CAD/CAM systems. Blanking, a metal forming process, is characterized by complete material separation, yet simulating the shearing process is complex due to the narrow shear band and the inadequacy of the fracture criteria. Key parameters such as sheet thickness, punch-die clearance, tool wear and punch geometry are studied to understand their interactions in the blanking process. Selecting the appropriate process parameters is crucial to ensuring that similar products made from different materials can be produced with high quality using the same mold. This study aims to explore the effects of sheet thickness, punch-die clearance and material type on the blanking process, as well as to predict the optimal parameters for achieving consistent quality. A mathematical model of the blanking process is developed and the Design of Experiments (DOE) method is applied to determine the optimal punch-die clearance for copper to ensure the production of high-quality components.