Modelling and Microstructural Aspects of Ultra-Thin Sheet Metal Bundle Cutting

Jarosław Kaczmarczyk,Aleksandra Kozłowska,Adam Grajcar,Sebastian Sławski

doi:10.3390/met9020162

Abstract

The results of numerical simulations of the cutting process obtained by means of the finite element method were studied in this work. The physical model of a bundle consisting of ultra-thin metal sheets was elaborated and then submitted to numerical calculations using the computer system LS-DYNA. Experimental investigations rely on observation of metallographic specimens of the surfaces being cut under a scanning electron microscope. The experimental data showing the microstructure of an ultra-thin metal bundle were the basis for the verification of the numerical results. It was found that the fracture area consists of two distinct zones. Morphological features of the brittle and ductile zones were identified. There are distinct differences between the front and back sides of the knife. The experimental investigations are in good agreement with the simulation results.

Highlights

In this paper the cutting problem of ultra-thin steel sheets arranged in bundles is considered
The numerical simulations concerning the cutting process of a bundle of sheets, the experimental investigations consisting of a series of microstructural images obtained by means of a scanning electron microscope (SEM)
In this paper the cutting problem was analysed for better understanding of the mechanisms In this paper the cutting problem was analysed for better understanding of the mechanisms involved

Summary

Introduction

In this paper the cutting problem of ultra-thin steel sheets arranged in bundles is considered. The sheets are made of C75S (carbon steel) cold rolled steel. The process of preparation of such thin sheets is complex and the cutting technology is sophisticated. Cutting of bundles is more efficient compared to cutting individual sheets, because it enables the cutting of many sheets with a single cutting tool passage. The most frequently occurring defects are the bends of the cut sheet edges, burrs as well as defects in the form of vertical scratches. In order to improve the cutting process, numerical investigations were carried out concerning mainly the use of the finite element method for numerical simulation of cut sheet separation together with experimental research aimed at verifying the obtained results

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Conclusion