Getting Sheet metal punch to reflect reality

[HDEAR]

I have created a sheet metal punch in IC based on an existing tool.

 

The punch works quite impressively, but the problem I have is that the cutout in the base sheet metal is exactly that of the punched part - which is punched down 8mm from the surface with a bent tab at the bottom. In reality, when you look direct onto the base plate, the cutout is about 1.5mm longer than the end of the tab looking in plan ( top ) view.

 

You will see by the photos of the actual punching done on 0.9mm st st what I mean.

 

The only way I have been able to mimic reality is to create a hollow slot, modify it and make the base plate punch that extra 1.5mm - see the first pdf, top slot circled in red.

 

Is there a way to either create the punch so it reflects reality or is there a tool that available that I am unaware of to do this just in one swoop?

 

I hope this all makes sense.

 

Harley

 

Edit: I altered the punch profile ( refer clip punch modified.ics ) which sort of works but it's after the fact ( having made the punch already ). It would be nice for IC to have pre-calculated that somehow when creating the punch with the forming tool - or is there part of the forming tool I could have used?

Clip_punch.ics

Clip_punch_modified.ics

Edited March 11, 2017 by HDEAR

[IronKevin]

Unless someone has a better idea, I think your Shape3 in Clip_punch_modified.ics is the bets option.

[HDEAR]

Unless someone has a better idea, I think your Shape3 in Clip_punch_modified.ics is the bets option.

44878[/snapback]

I thought so. I guess I'm expecting a bit too much for IronCad to automatically work out the amount of deformity due to stretch and draw when punching as there are so many factors to consider. Even making the calculation by hand is daunting.