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    THEORETICAL AND EXPERIMENTAL INVESTIGATION OF THE PUNCHING PROCESS OF DP-AL PLATE COMPOSITES BY USING DIFFERENT PUNCH TIPS
    (2023-05) Belras Ali, Khalil Abubaker
    Although there has been a great development in laser, water jet and similar sheet metal cutting processes, cutting/drilling processes continue to gain more importance as drilling and cutting are the most used applications in the industrial field. On the other hand, a major challenge when using punching/punching sheet metal is overcoming the shear force required for high-strength and bonded sheets. Increased cutting forces lead to higher performance requirements expected from the press machine and cause increased wear on the punch tool and die. The quality and condition of the cut area are also very important as a separate phenomenon. One of the techniques used to reduce the punch cutting force needed is to change the punch type, which is done by changing the punch shape, especially the cutting angle. This study aimed to produce laminated composites of three different Dual Phase steels and Al sheets with enhanced strength by explosive welding and then to examine the punch-cutting process of these three quality laminated composite sheets and the shear effects on the material. Sheet steels were commercial grades DP600, DP1000 and DP1200. The Al plate was commercial Al 1100 grade Al alloys. Base metals were used to produce laminated Al-DP steel composite by explosive welding. Cutting tests were conducted in punching operations using five punch slip angles, 0°, 16°, R1, R2 and V16°. The force graphs corresponding to the procedure times were obtained thanks to the load-cell computer system in Punching operations. Experimental studies meaning shear analyses have also been evaluated via finite element method simulations. Besides, the punching results showed good agreement between modelling and experimental punching forces. The highest cutting forces were observed when the punch was ""0"" (flat-punch, 0°). The other punch forms obtained the lowest cutting forces using punch R2, V16, R1, and 16, respectively. Moreover, the punched surfaces have been observed by comparing the force-time graphs. In addition, this study is a pioneer in the literature on its concepts, such as explosive weld materials and their punch process.