• Transactions of Materials Processing
• /
• v.19 no.5
• /
• pp.290-295
• /
• 2010

Shaving technology is one of the significant metal forming technologies which can make the smooth and fine sheared surface of products after shearing process. The sheared surface on the side wall of the cutting edge is very important because it functions as a basic surface for measuring the dimensions of product. Effective sheared surface after shaving can be influenced by several working variables such as shaving allowance, shaving clearance, type of material and profile of cutting edge. The influence of these variables on shaving characteristics was investigated in this study. A cut-off die to make the simplified gear-shaped products was manufactured. Three kinds of sheet metals (AL5052, SPCC and SAPH440) of 3mm thickness were firstly sheared and then shaved for four shaving allowances and three sharing clearances. It was shown through experiments that the optimum working condition to give the maximum effective sheared surface in shaving was found ; Shaving allowance is 0.2mm and Shaving clearance is 0.01mm.

• Journal of Welding and Joining
• /
• v.17 no.2
• /
• pp.66-75
• /
• 1999

Weld bead quality in tailored blank(TB) is critically affected by edge preparation of sheets. The edge quality of prepared sheets for TB can be classified into straightness and the cross section quality of sheared plane such as a ratio of shear face, shear plane angle, etc. In order to have a good edg quality for butt-welding sheets, precision shearing will be recommended. In this paper, the feasibility of a conventional mechanical shearing as the edge preparation for tailored blanks is studyied. It reveals that fine shearing may not be the unique solution as it is generally accepted. To obtain the good shearing condition with a conventional mechanical shearing, experiments were carried out using Tahuchi method. The major parameters affecting a sheared contour are the clearance between upper blade and lower blade, and shear angle. The optimal shearing condition yields a very good straightness along the entire length of the cut, which gives a butt joint gap less than 10% of the base material thickness. The good cross section of sheared plane is also achieved in the optimal shearing condition such as a ratio of the shear face above 65%, a cross section's shear plane angle above 85%, little burr, which is providing finally good weld beads.

• Transactions of Materials Processing
• /
• v.26 no.5
• /
• pp.293-299
• /
• 2017

In this paper, finite element stamping analysis was carried out for the front lower arm to examine the applicability of solid element with damage theory to predict shear fracture phenomena induced by sheared edge as well as deformation mechanisms. Mechanical properties related to deformation and damage theory were determined from tensile test. Shear fracture was predicted by normalized Cockcroft-Latham model with initial imposition of the damage value along the sheared edge. Simulation results illustrated that the analysis with solid element and damage theory predicted edge profile, strain distribution, and forming load more accurately than the analysis with shell element. Simulation with solid element can also predict the shear fracture more exactly comparing to analysis with shell element and forming limit curve.

• Design & Manufacturing
• /
• v.16 no.3
• /
• pp.28-33
• /
• 2022

The recent increasing application rate of advanced high-strength steel(AHSS) for automotive parts makes it difficult to ensure the durability of forming tools. Significant load and friction generated during the piercing process of AHSS increase the wear rate and the damage degree to dies. These harsh process conditions also yield product failures, such as dimensional inconsistency of pierced holes and insufficient quality of hole's sheared edge. This study analyzed the effect of punch wear on the sheared surface of pierced parts and the forming load during the piercing process. Wear-shaped punches showed approximately 20% higher piercing load than normal-shaped punches, and the rollover ratio of the sheared surface also increased. It is considered that the dull edge of wear-shaped punches does not penetrate directly into the material but shears after tensioning it in a piercing direction. In addition, wear-shaped punches experienced compressive load even after completing the piercing process during the down-stroke and tensile load during the up-stroke. This load variation is related to the smaller diameter piercing holes produced by wear-shaped punches compared to normal-shaped punches. Thus, we demonstrated the predictability of the wear level of dies through a comparative analysis of the piercing load pattern.

• Transactions of Materials Processing
• /
• v.32 no.2
• /
• pp.61-66
• /
• 2023

The quality of the sheared surface affects the stretch flangeability of steel sheet. The quality of sheared surface is influenced by several process factors such as die clearance, shape of cutting edge, use of counter punch, and shear. In this paper, the influence of these shearing process factors on the stretch flangeability of the HSS (DP980) was analyzed through a shearing and a stretch flangeability test. When the die clearance was 10%, the effect of these shearing process factors on the stretch flangeability was the greatest, and the use of an acute angle blade was found to be more advantageous in the stretch flangeability than a right angle blade. It was found that the stretch flangeability was improved when active bending was applied during shearing.

• The Transactions of The Korean Institute of Electrical Engineers
• /
• v.57 no.10
• /
• pp.1752-1758
• /
• 2008

This paper deals with the reduction of friction torque in permanent magnet motors by using the heat treatment of stator core. The stator core is made of electrical steel sheared by the punching die. From the punching process, large mechanical stress acting on the edge of stator tooth induces significant plastic and elastic deformation and then cause the change of magnetization properties. Then, the mechanical and magnetic unbalance in the sheared region of stator tooth produced by material cutting has influence on the friction torque. This paper investigated the effect of the punching process on the magnetization process and the mechanical deformation, and then proposed the stress relief annealing method for the reduction of friction torque among one of motor characteristics.

• Proceedings of the KIEE Conference
• /
• 2008.07a
• /
• pp.695-696
• /
• 2008

This paper deals with the reduction of DC component of cogging toruqe by using the heat treatment of the stator core. The stator core is made of electrical steel sheared by the punching die. From the punching process, large mechanical stress at the edge of stator tooth induces significant plastic and elastic deformation and influences magnetic properties. Then, these phenomenon in the sheared region has influence on the magnetic unbalance in the air-gap of motor. This paper investigated the effect of the punching process on the magnetization process and the mechanical deformation and proposed the stress relief annealing method for the reduction of friction torque among one of motor characteristics.

• Proceedings of the Korean Society for Technology of Plasticity Conference
• /
• 2001.05a
• /
• pp.231-234
• /
• 2001

Shearing, including blanking, trimming, piercing, etc, is one of the most frequently used processes in sheet metal manufacturing. In this paper, an individual set of tooling with an in-die sensor was designed and precisely fabricated to carry out the experiment for the shearing process investigation. Through various experiments, it has been examined the influence of process parameters such as clearance, edge material properties and pad configuration. Since the tension between the part and the scrap increases when the clearance increases, the clearance should be selected properly in order to reduce the burr height. Also removal of the lower pad makes the sheared surface worse and the shearing system unstable. The shearing force increases when the clearance decreases and the friction of the tooling material decreases. Dynamic reaction force is also important to obtain the fine sheared surfaces.

• Journal of the Korean Society of Manufacturing Technology Engineers
• /
• v.25 no.3
• /
• pp.177-181
• /
• 2016

Hot shearing is a method of producing various high-quality planar machine parts by using reduced punch load. In order to predict the results of this process, the deformation behavior of work material at elevated temperatures need to be studied. In this research, a tensile test was carried out for 5052 aluminum alloy at high temperatures of $240-540^{\circ}C$ and strain rates of 0.001-0.1/s. The results of the tensile tests were studied to predict the deformation of the alloy during the hot shearing process. The results showed that hot shearing within a temperature range of $340-440^{\circ}C$ and a strain rate rage of 0.001-01/s will be the most effective in reducing punch load and increasing the sheared edge in the case of 5052 aluminum alloy.

• Transactions of Materials Processing
• /
• v.19 no.6
• /
• pp.337-343
• /
• 2010

Current need of weight reduction in automotive part increases the application for high strength steel (HSS). The various types of high strength steels have been used to produce chassis part, control arms and trailing arms for weight reduction and increasing of fatigue durability such as dual phase steel (DP) and ferrite bainite steel (FB). But, DP and FB steels have proven to show inferiority in durability as well as press formability. Edge cracking occurred often in flange forming and hole expansion processes is the major failure encountered. This paper discussed the behavior of edge stretchability of high strength steel of DP and FB steels. Experimental works have been conducted to study the effect of punch clearance and burr direction on hole expansion ratio (HER). Also finite element simulation (FEM) has been preformed to clarify the mechanism of flange crack and support the experimental results on HER of DP and FB steels. It was simulated the whole process of blanking process following by hole expansion process and ductile fracture criterion named the modified Cockcroft-Latham model which was used to capture the fracture initiation. From the hole expansion tests and FEM simulation studies it was concluded that ferrite bainite steel showed better stretch-flangeability than dual phase steel. It was attributed to the lower work hardening rate of ferrite bainite steel than dual phase steel at the sheared edge.