Investigation of Double-Layer Blanking Technology for Production of Sheets for the Rotor and Stator of an Electric Motor

The optimization of blanking technology using the novel double-layer configuration allows for increased production capacity, but it introduces certain drawbacks, which mainly affect the quality of the blanked parts. In this study, the effect of this blanking configuration was evaluated on two types of electrical steels intended for the production of rotor and stator cores. A numerical simulation of the blanking process was conducted using the Simufact Forming 2022 software. Analysis of the experimental results showed that blanks produced by the double-layer configuration exhibit significantly increased dishing deformation, more than 3.5 times for material B and more than nine times for material C when compared with the dishing increment in single-layer samples. Each layer of the configuration also produces different sheared edge shapes with different proportions of zones. Neither of the layers corresponds fully to the results produced by conventional blanking. Based on the results of the simulations of this process, it can be concluded that this simulation software can predict double-layer blanking with limited accuracy as most differences between measured parameters of the sheared edge relative to the nominal thickness are within 20%.