Accuracy of Modified Johnson–Cook Modelling of the Blanking Process through Experimental and Numerical Analysis

Metal parts undergo a blanking test that involves experimentation with different process parameters across multiple levels. The presence of uncontrolled burrs (measured as Hbv) significantly affects the precise geometry of the blanked parts, making it a primary concern in precision blanking. Moreover, the maximum blanking force (Fmax) holds considerable significance, as it aids in forecasting fracture mechanisms and plays a pivotal role in the design of blanking tools. The aim of this study is to assess the predictive capabilities of an elasto-plastic model coupled with damage in capturing the behavior of sheet material during the blanking process. Additionally, integrating the rate-dependent aspect into the model is crucial for accurately modeling the mechanical behavior of sheet metal. Our focus remains on demonstrating the efficacy of the model in predicting blanking force and burr formation. The numerical model incorporates modified plasticity and damage Johnson–Cook models to achieve this objective, considering the combined effect of strain and strain rate fields in the sheet blanking process. Experimental validation proves the efficacy of the proposed model in accurately predicting blanking outcomes. The experimental results confirm the model’s capability to provide a consistent prediction of the blanking force and burr dimensions. In addition, it was proved experimentally that the sheet thickness has the most influence on Hbv and Fmax.