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Wear is one of the common failure modes of blanking die. For pre-vibration cover, a geometric model of blanking was established by Pro/E software, and the blanking process of sheet metal was simulated by Deform-2D software. Then, the stress distribution of blanking process was analyzed, and the influences of blanking process parameters on the length of smooth zone and wear depth of punch were studied. The simulation results show that the length of smooth zone shortens with enlarging die clearance and radius of punch cutting edge, while it increases with the increasing of blanking speed. However, the wear depth of punch decreases with the increasing of die clearance, while it increases with the increasing of radius of punch cutting edge and blanking speed. In addition, a stamping progressive die was designed to verify the simulation results with the length of smooth zone at simulation value and experimental value of 0.569 mm and 0.518 mm respectively, and the relative error between simulation value and experimental value is 9.85%. Thus, the feasibility of die wear measured indirectly by the length of smooth zone is verified.
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