Evaluate the effectiveness of die clearance and die radiuson burr height and stress of aluminum AA1050 in progressive die by simulation and experiment

Sheet metal forming is one of the most valuable processes in manufacturing. Its products are used in mechanical engineering, the auto industry, warehouses, civil engineering, and architecture. Shearing and forming are two of the primary operations in sheet metal processing. They are the first fundamental stage in processing sheet metal. The quality of the forming product is a manufacturing parameter. Shearing and forming processes, including progressive, die clearance, and radius, are the main factors influencing the quality. In this paper, the effects of die clearance and die radius on burr height and stress of aluminum are investigated by simulation and experiment. The findings revealed a direct correlation between die clearance and stress on the workpiece, with smaller clearance inducing higher stress and lower burr formation. The clearance exhibited minimal influence on stress and deformation. A 6% die clearance yielded the lowest burr height. Increasing the fillet radius mitigated stress concentration, diminished the critical cross-sectional area, and lessened deformation; however, it resulted in a less defined product shape.