Adaptive wear model for shear-cutting simulation with open cutting line

Shear-cutting is one of the most important manufacturing processes involving sheet metal. The local pressure on the tools as well as the sliding speed between tools and work piece are much larger in shear cutting than in typical forming processes such as deep-drawing. This makes the prediction of to...

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Bibliographic Details
Published inWear Vol. 386-387; pp. 17 - 28
Main Authors Cha, Wan-Gi, Hammer, Tobias, Gutknecht, Florian, Golle, Roland, Tekkaya, A. Erman, Volk, Wolfram
Format Journal Article
LanguageEnglish
Published Amsterdam Elsevier B.V 15.09.2017
Elsevier Science Ltd
Subjects
Cold working
Computer simulation
Cutting wear
Damage model
Deep drawing
Dual phase steels
Duplex stainless steels
Fatigue tests
Friction
Interpolation
Manufacturing
Metal sheets
Shear
Shear-cutting
Sheet material
Tool life
Wear prediction
Wear resistance
Damage model
Wear prediction
Friction
Shear-cutting
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Summary:Shear-cutting is one of the most important manufacturing processes involving sheet metal. The local pressure on the tools as well as the sliding speed between tools and work piece are much larger in shear cutting than in typical forming processes such as deep-drawing. This makes the prediction of tool life more critical in a shear-cutting simulation, in contrast to a forming simulation. A FE-program for wear prediction was used so far in the forming simulation. This tool was adjusted to the shear-cutting process through modifications of the shear-cutting simulation and of the interpolation algorithm to stabilize the wear calculation for the process. Endurance tests for the validation of the simulation results were performed with a hardened cold working steel (1.2379, 58 HRC) as tool material and a dual phase steel (DP600) with a thickness of 1 mm as sheet material. The FE-tool permits the qualitative prediction of the wear of the active elements in shear-cutting processes. •Adjusting of the REDSY to the shear cutting by the smoothing the worn surface.•Validation of the shear cutting and wear simulation by the endurance test.•Elastic tool can reproduce the influence of the friction on the face wear.•The wear prediction by the different wear coefficients on different positions.
ISSN:0043-1648
1873-2577
DOI:10.1016/j.wear.2017.05.019