Abstract
Asymmetric plunge cutting by using a grooved knife edge plate was proposed for advanced die cutting of a polycarbonate (PC) sheet. By varying the tip angle αU and the tip thickness w U of knife edge in the counter plate, and combining a standard steel cutting rule of 42° center bevel blade, a cutting load response of PC sheet was experimentally investigated, and the deformation was also observed by a CCD camera. Furthermore, an FEM simulation was carried out by varying the lower tip thickness for revealing the effect of interference of lower grooved counter plate. Through this work, the following were found: 1) there were two deformation modes of sheared profile; 2) the lower tip thickness w U was a primary factor, compared to the lower tip angle of αU; 3) the equivalent wedge angle effect was revealed with respect to the upper/lower angles α and αU, while the PC sheet was bent up by the lower knife indentation.
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