Abstract
This paper modelled the cutting process of a bundle consisted of ultra-thin cold-rolled steel sheets using a guillotine. The geometry of a cutting tool with given dimensions was assumed. A bundle of sheets being cut was modelled as deformable, the cutting tool was rigid, and the finite element method along with computer system LS-DYNA was employed. Numerical simulations of the complex state of stress and of the corresponding complex state of strain were carried out. Cutting processes belong to fast changing physical phenomena, and therefore, highly nonlinear dynamical algorithms were applied in order to solve this particular problem. Experimental investigations were also conducted by means of the scanning electron microscopy. It was found that the fracture region consisted of two distinct zones: brittle and ductile separated from each other by the interfacial transition. Morphological features of the brittle, ductile, and the transition regions were identified. The ductile and brittle zones were separated at the depth of ca. 1/5 thickness of the cut steel sheet. Finally, the numerical results obtained by usage of the finite element method as well as experimental ones in the form of microscopic images were compared, showing quite good agreement.
Highlights
The cutting process is very often used in everyday life as well as in many branches of industry—for example, in the printing industry as matrices for printing books, newspapers, magazines, etc., in the production of metal cans as well as foil for food storage and in automotive industry for cutting out car bodies
The experimental results have been obtained in the form of images of a blade of a cutting tool and the material being cut, applying scanning electron microscopy
To show the mechanism of cutting of sheets arranged in a bundle, the author’s physical models and corresponding to them the mathematical ones have been elaborated by means of the finite element method
Summary
The cutting process is very often used in everyday life as well as in many branches of industry—for example, in the printing industry as matrices for printing books, newspapers, magazines, etc., in the production of metal cans as well as foil for food storage and in automotive industry for cutting out car bodies. It is rather impossible to maximise the height of a bundle of sheets understood as an increase of the number of sheets being cut with a simultaneous reduction of the force required for cutting, reduction of the deflection in edge bending, and a decrease in the frequency of random occurrence of the craters as well as in the size of scratches. For the optimisation of the layout of rectangular parts, they used two design objectives involving minimisation of the length of the mother sheet and the total number of cuts required to obtain all the parts from the mother sheet They applied a multi-objective genetic algorithm to study both guillotine and non-guillotine cutting cases using a binary representation of the variables. The geometry changes make it possible to reduce the undesirable plastic region in comparison with zone the size of the by plastic zone producedcutting by a non-symmetrical cutting tool. On the the basis basis of of the the current current paper paper and and earlier earlier author’s author’s sheets work on on cutting cutting using using aa non-symmetrical non-symmetrical cutting cutting tool tool under almost the same cutting conditions [17], work one can canachieve achievea asignificant significant reduction of the undesired height of a plastic responsible for one reduction of the undesired height of a plastic regionregion responsible for many many defects and simultaneous increase of a zone, brittlewhich zone, is which is strongly defects and simultaneous increase of a brittle strongly desired.desired
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