Numerical simulation and optimization of clearance in sheet shearing process

An analysis model to simplify the shearing and blanking process was developed. Based on the simplified model, the shearing process was simulated by FEM and analyzed for various clearances. An optimum clearance in the process was determined by new approach based on orientation of the maximum shearing stress on the characteristic line linking two blades, according to the law of crack propagation and experiments. The optimum clearance determined by this method can be used to dictate the range of reasonable clearance. By the new approach, the optimum clearance can be obtained conveniently and accurately even if there is some difference between the selected points, where the initial crack is assumed originated, and the actual one, where the initial crack occurs really.