| Budget Amount *help |
¥3,400,000 (Direct Cost: ¥3,400,000)
Fiscal Year 2006: ¥1,100,000 (Direct Cost: ¥1,100,000)
Fiscal Year 2005: ¥2,300,000 (Direct Cost: ¥2,300,000)
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| Research Abstract |
The machining accuracy of the shearing process is evaluated primarily based on the shape of the cross-section and dimensional accuracy. In addition, the workpiece material, the restraint condition of the workpiece, the clearance between the punch and die, and the process speed, for example, are considered as machining factors that affect machining accuracy. Based on several experimental and FEM studies, the clearance is reported to have the most significant influence on the machining accuracy.
However, there has been no report regarding the effect of uneven clearance due to misalignment of the positions of the punch and die. One reasons for this is that uneven clearance under the circumstance of a thick workpiece does not have a serious effect on the machining, because the clearance is usually given as a function of the workpiece thickness. However, considering that the present demand for thin shearing products is increasing, it has become dangerous to ignore misalignment of the tool position. Therefore, methods of adjusting the initial tool position using electrostatic capacity or wire electric discharge grinding in order to avoid uneven clear ance have been developed. However, these methods have drawbacks such as lack of accuracy or the inability to use commercially available tools for adjustment.
Therefore, in the present study, a new adjustment mechanism of initial tool position is devised, and a prototype punch press with the newly developed adjustment mechanism is developed. In addition, the influence of the initial tool position adjustment on the machining accuracy is qualitatively confirmed. Processing experiments are then conducted under the condition that the initial tool position is adjusted, and the profile of the cross-section and diameter of holes are measured in order to investigate the machining accuracy for several clearances.
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