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Fabrication of clean cut surface on high strength steel using a new shaving die design

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Abstract

A shaving process is commonly applied to achieve a smooth cut surface thorough the workpiece thickness and a square cut-edge, also known as a finishing operation. However, this process is rarely successful for high-strength steel sheets, which is a major problem. In the present study, finite element method (FEM) simulation was used to clarify the main causes of this problem by comparing the shaving mechanisms between medium carbon steel grade SPCC (JIS) and high-strength steel grade SPFH 590 (JIS). Results show that in the case of SPFH 590 based on material flow, stress distribution, and strain distribution analyses, the shaved chip was difficult to form by sliding along the punch face. Moreover, the tensile stress generated in the shearing zone was increased and readily generated cracks. The shaving process was developed in the present study by generating the cutting-edge angle and rake radius on the punch. The cutting edge angle was designed to generate high compressive stress in the cutting-edge vicinity and shearing zone, and the rake radius was designed to tear a shaving allowance off and move it along the rake radius instead of moving downward along the punch movement direction, thereby decreasing the tensile stress in the shearing zone. Under these mechanisms, the increases in the generated tensile stress in the shearing zone could be delayed, and cracks could thus be prevented. The effect of the punch geometry on the cut surface characteristics and cutting forces were also investigated. Laboratory experiments were performed to validate the FEM simulation results. Experimental results agreed well with the FEM simulation results. Therefore, a smooth cut surface thorough the workpiece thickness of high-strength steel sheets could be successfully achieved by using the developed shaving process.

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Acknowledgements

This study was partially supported by Grants from The Thailand Research Fund under Grant No. RSA6180047 and The Higher Education Research Promotion and National Research University Project of Thailand, Office of the Higher Education Commission under Grant No. 57000618. The authors would also like to thank Miss Wiriyakorn Phanitwong, Ph.D. for her assistance during this study.

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Authors and Affiliations

  1. Dept. of Tool and Materials Engineering, King Mongkut’s University of Technology Thonburi, Bangkok, Thailand

    Sutasn Thipprakmas & Arkarapon Sontamino

Authors
  1. Sutasn Thipprakmas
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  2. Arkarapon Sontamino
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Corresponding author

Correspondence to Sutasn Thipprakmas.

Additional information

Recommended by Editor Hyung Wook Park

Sutasn Thipprakmas, D.Eng., is a Professor at the Department of Tool and Materials Engineering at King Mongkut’s University of Technology Thonburi, Thailand. His research interests include plastic deformation and metal forming process.

Arkarapon Sontamino is a Ph.D. candidate at the Department of Tool and Materials Engineering, King Mongkut’s University of Technology Thonburi, Bangkok, Thailand.

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Thipprakmas, S., Sontamino, A. Fabrication of clean cut surface on high strength steel using a new shaving die design. J Mech Sci Technol 34, 301–317 (2020). https://doi.org/10.1007/s12206-019-1231-z

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  • DOI: https://doi.org/10.1007/s12206-019-1231-z

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