During the manufacturing of rotor and stator stacks, that are produced on a progressive sheet metal stamping tool, product defects may occur. These errors can include dimensions that fall outside of the tolerance range, curved products, and curved clip grooves. Clip grooves connect sheet metal pieces together to form a stack. It is believed that one of the influences on these errors is the distance between the stripper and the die plate. These are the two plates between which the sheet metal runs. To investigate this hypothesis, we will test three different distance configurations: a triple thickness of sheet metal, a double thickness of sheet metal, and a stripper plate pressed against the sheet metal. To do this, we will create a small prototype progressive tool with three cutting moves. The first move will create the middle hole. The second move will create four clips that are offset by 90 degrees from each other. On the final move, we will obtain the final piece. We will then simulate the effects of distance between plates in LS-DYNA and perform practical tests on the tool with different distances using a universal testing machine. At the end, we will determine the most suitable distance between the plates, and we will also confirm whether simulation models can accurately describe the actual state.
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