In order to meet the production requirements of low energy consumption

high efficiency and low cost in the aviation. The combination of ABAQUS finite element (FE) simulation with experimental research is used to study the blanking of diamond-shaped plastic plugs for aviation fuel system accessories. Firstly

through the blanking experiment of common steel molds

it is found that there are the defects such as large collapse angle

serious depression and unevenness of the section. Secondly

simulation analysis of the fracture characteristics and stress-strain state of its section

and it is found that: 1) the PTFE sheet is punched with a common steel die

and it has a large difference in the stress triaxiality of the three areas of the section (fracture area

crack area and fillet area). 2) After springback

the crack area shrinks inward

the fracture area and the fillet area protrude outward at the edge

resulting in a large groove on the cross-section. 3) An optimization scheme to reduce the volume stress in the blanking by changing the geometric shape of the die is put forward. Finally

Combining the oblique blade shearing method with the steel die structure

a new oblique blade blanking model structure is designed

and through the simulated and experimental research

the angle of the oblique blade is optimized to be 20°. It is found that the section quality of the diamond-shaped plastic plug is significantly improved by experimental

which meets the production requirements

and provides a guidance for subsequent fine blanking of various non-metals.