A novel approach for characterising the cause of disc formation by the shear cutting process in a punching machine

Abstract

The objective of this paper is to validate a method for identifying the cause of disc formation by numerical and experimental investigations for a single-stage shear cutting process in a tool-bound punching machine. To this end, first a 2D simulation model for the deep-drawing steel DC01 is developed, which enables the sophisticated requirement of tracking the material flow behaviour in the cutting process to be met by using the FEM Software DEFORM. Furthermore, the plastic flow behaviour is measured in an equivalent experiment with strain gauges near the cutting process. Then, the measurement results from the experimental investigation are contrasted with those from the simulation and compared for reliability at the measuring position of the strain gauges. The main contribution of this paper is a numerically and experimentally performed comparative study, in which the verified results of the first investigation near the shearing process are transferred into the cutting area and are validated subsequently.