Part cracking or fracture during progressive stamping is commonly related to unstable material flow, excessive shear displacement, inadequate blank holding, or uneven load distribution. These conditions can result in localized deformation and stress concentration, ultimately reducing the structural integrity of the stamped component.
Die edge chamfering can be used to reduce localized stress concentration, but corrective action should not be limited to die modification. A systematic review of the forming conditions is recommended.
Key parameters to evaluate include blank holder force, die clearance, punch-to-die alignment, material flow, and forming load distribution. If insufficient blank holding is identified as the primary cause, increasing the blank holder force within the appropriate process range can improve material restraint and reduce unwanted material movement.
For more complex cases, further optimization of the die geometry, forming sequence, clearance, and process parameters may be necessary to achieve stable, repeatable production.
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