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The quality of hole in the sheet metal manufacturing is dependent on the die design and process parameters. In conventional piercing process, the hole surface features normally consist of the die-roll, shear surface, cracks, and burr. The secondary operations such as reaming, shaving, and grinding are needed for achieving the smooth hole surface without any cracks. In roller chain the link plate is manufactured by conventional blanking and piercing operation. In roller chain assembly only shear zone of hole comes in contact with pin, so there is less contact area between pin and bush. Due to this there are uneven bending stresses and shear stresses in the pin while chain is in working condition. Therefore, elongation occurs in the chain due to pin and bush gets wear, which reduces the breaking load and life of chain. The aim of this study is to increase the contact area between bush and pin which automatically will increase the life and the breaking load of the chain. The fine-piercing process, referenced to the fine-blanking principle, is used to produce the precise-dimensioned holes in the roller chain link plate parts with smooth-cut surfaces over the whole material thickness in a single operation. In this study, the stresses on link plate and pin were investigated by finite-element method (FEM) for both conventionally piercing and fine piercing of link plate. The breaking load of chain was checked on UTM for both roller chains when conventionally pierced link plate and fine pierced link plates are used in assembly of chain. The results showed that an application of fine piercing processes in link plates of roller chain results superior fine-pierced hole surface could be achieved. Furthermore, the use fine piercing process increases shear length in hole. The increase in shear length increases the contact area between pin and bush, therefore wear between pin and bush reduces. The reduction in wear minimizes stresses on pin and link plate and increases breaking load and life of chain.
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