Investigation of effective parameters on oxygen free high conductivity copper deformation based on cutting molds design and numerical approach

This paper investigates the effect of using different values of selected parameters on directional deformations of the oxygen free high conductivity copper rectangular shape product.These parameters include cutting velocity, initial sheet temperature, and punch fillet radius.The article introduces a comprehensive study of cutting mold design procedures and analysis in terms of the directional deformation of the product.The deformations have been analyzed numerically to determine the highest and lowest values of the product utilizing analysis system (ANSYS) software 18.1.The analysis shows the rise in the deformation as the cutting velocity increases from 40 mm/s to 80 mm/s.Deformation is lowest at 0 C and peaks at 80 C.The smallest deformation with a punch fillet radius of 0.1 mm, while a 0.9 mm radius maximizes it.The deformation increases significantly when the velocity increases from 70 mm/s to 80 mm/s and fillet radii rise from 0.7 mm to 0.9 mm.The higher velocities above 60 mm/s and high temperatures over 60 C result in greater product deformation.The significant rise in the deformation value occurs at temperatures above 60 C and fillet radii above 0.7 mm, while the minimal value occurs at temperatures below 40 C and fillet radii below 0.3 mm.Also, it showed that deformation increases by 30-40% at high cutting velocities, initial sheet temperatures, and fillet radii.The cutting mold model is validated by comparing the current numerical results with available published data for copper sheet blanking.The directional deformations of the present numerical modeling and the experimental work of the available literature appeared in a good agreement with an error value not exceeding the range of 1-3%.