Hybrid analysis of tool geometry and process noise in fine blanking through simulation and experiment

Hybrid analysis of tool geometry and process noise in fine blanking through simulation and experiment | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Hybrid analysis of tool geometry and process noise in fine blanking through simulation and experiment Daria Gelbich, Frank Schweinshaupt, Philipp Niemietz, Tim Herrig, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8711483/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract In fine blanking, a mass production process for safety-critical components, a discrepancy exists between static modeling techniques and the stochastic nature of real-world measurements, often termed process noise. This work combines Finite Element Method simulations with data from industrial-scale fine blanking experiments, featuring long stroke series across multiple coils with systematically varied die clearances. The analysis shows a strong correlation between force curve characteristics and the formation of tears, a relationship that holds across all tested geometries. In contrast, only weak and inconsistent correlations were found between the force signal and the resulting die roll. This weakness is explained by the finding that multiple physical effects, such as material strength and friction, have competing influences on die roll that are not separable in the single force signal. These results demonstrate that the utility of the force signal for quality prediction is highly dependent on the tool geometry, providing a basis for more reliable tool design strategies in fine blanking. Fine blanking FEM simulation process noise tool geometry Full Text Additional Declarations The authors declare no competing interests. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8711483","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":581216530,"identity":"de7aa64d-a1f4-40d1-b36a-79f7ff4ed88e","order_by":0,"name":"Daria 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This work combines Finite Element Method simulations with data from industrial-scale fine blanking experiments, featuring long stroke series across multiple coils with systematically varied die clearances. The analysis shows a strong correlation between force curve characteristics and the formation of tears, a relationship that holds across all tested geometries. In contrast, only weak and inconsistent correlations were found between the force signal and the resulting die roll. This weakness is explained by the finding that multiple physical effects, such as material strength and friction, have competing influences on die roll that are not separable in the single force signal. 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