An Investigation into Orthogonal and Oblique Cutting Processes

Abstract

The cutting process may be divided into two major types. The one type is called as straight angle cutting, where blade is in continuous contact with metal sheet from one side of edge to another side of the edge at the beginning of the cutting process. The another type is known as shearing, where the blade edge is oblique and progressively proceed from one edge of metal sheet to other end of metal sheet during cutting process. The present study has investigated straight angle cutting and shearing processes by using virtual environment of software ANSYS 19-R. An explicit dynamic FEM analysis was used in various simulations of punching and shearing investigations. The current study has two four parts. In first part, impact of attack angle variation on stress generated on tool and work piece has been investigated. Both punching and shearing processes have been simulated in software environment to understand and differentiate both cutting processes. In second part, straight angle tool was used to create straight angle cutting environment. Various cutting parameters including tool, metal sheet and cutting process parameters have been investigated for straight angle cutting. In third part, oblique angle tool was used to create shearing environment. Various cutting parameters including tool, metal sheet and cutting process parameters have been investigated for shearing. In fourth part, straight angle cutting and oblique angle cutting process has been compared to find out impact of various parameters on straight angle cutting and shearing and how these may be differentiated. The cutting process is complex and depends upon tool, metal sheet and cutting process parameters. Tool parameters investigated in present study include tool edge angle, tool attack angle, tool material and tool thickness. The metal sheet parameters affecting cutting process have been investigated in the present study and include metal sheet material and metal sheet thickness. Cutting process parameters investigated in present study include cutting process speed and friction between metal sheet and tool. Both punching and shear cutting simulations has been designed in present study by considering guillotining machine.