Sliver Generation Reduction in Trimming of Aluminum Autobody Sheet

Ming Li

doi:10.1115/1.1540113

Journal of Manufacturing Science and Engineering | Volume 125 | Issue 1 | TECHNICAL PAPERS

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TECHNICAL PAPERS

Sliver Generation Reduction in Trimming of Aluminum Autobody Sheet

Ming Li, Mem. ASME

[+] Author and Article Information

Ming Li

Alcoa Technical Center, Alcoa, Inc., Alcoa Center, PA 15069

J. Manuf. Sci. Eng 125(1), 128-137 (Mar 04, 2003) (10 pages) doi:10.1115/1.1540113 History: Received February 01, 2001; Revised March 01, 2002; Online March 04, 2003

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References

Figures

Optical micrograph of a piece of hair-like sliver generated in a production line

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Microstructure difference between aluminum and steel sheets. Aluminum sheets contain appreciable amount of constituent particles.

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Schematic of the trends of cutting angle effects for aluminum and steel sheets

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(a) Morphology of the third type sliver, as indicated by the arrows. Note that the picture background is the adhesive cellophane tape. (b) Two pieces of third type slivers still attached to the cut surface of a “part.”

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Clearance, blade sharpness and cutting angle are parameters considered

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Sliver damaged aluminum hood outer panels

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Schematic of the trends of clearance effects with optimal cutting angles for aluminum and steel sheets

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Schematic trimming configurations of the conventional (above) and the new (below)

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Optical micrographs of the first type sliver: (a) the smooth and shiny surface side, (b) the rough surface side. Note that the picture background is the adhesive cellophane tape.

View Large | Save Figure | Download Slide (.ppt)

Scanning Electron Microscope (SEM) micrograph of the rough fracture surface of a first type sliver

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Sketch illustrating the “part” and the “scrap” of a trimmed sheet

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Two pieces of first type slivers barely hanging-on the edge of a “scrap.” The micrograph views from the top-down direction, as shown schematically. The smooth and shiny surface of the slivers resulted from contact with blade.

View Large | Save Figure | Download Slide (.ppt)

Schematic of the trends of blade sharpness effects with optimal cutting angles for aluminum and steel sheets

View Large | Save Figure | Download Slide (.ppt)

Two pieces of first type slivers barely hanging-on the edge of a “scrap.” The micrograph views from the bottom-up direction, as shown schematically. The rough surface of the slivers is fracture surface.

View Large | Save Figure | Download Slide (.ppt)

Scanning Electron Microscope (SEM) micrograph of the fracture surface of a first type sliver hanging-on the edge of a “scrap.”

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Optical micrograph of the cross-section (as-polished) of an interrupted test specimen showing a C-shaped crack formed in the sheet. The dark area was occupied by the blade. The light area is the sheet material being trimmed half-way.

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Optical micrographs of a second type sliver: (a) generated in the lab, (b) generated in a production line. Note that the picture background is the adhesive cellophane tape.

View Large | Save Figure | Download Slide (.ppt)

Origins of the second type sliver: cutting blade interaction with the secondary burnish area of the cut surface on a “part.” The micrograph views the cut surface from the direction as schematically shown. A second type sliver still attached to the secondary burnish area.

View Large | Save Figure | Download Slide (.ppt)

Origins of the second type sliver: cutting blade rubbing-off from the burr area of the cut surface on a “part.” The micrograph views the cut surface from the direction as schematically shown. Two pieces of second type sliver still attached to the burr area.

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Li M. Sliver Generation Reduction in Trimming of Aluminum Autobody Sheet. ASME. J. Manuf. Sci. Eng. 2003;125(1):128-137. doi:10.1115/1.1540113.

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Sliver Generation Reduction in Trimming of Aluminum Autobody Sheet

References

Figures

Optical micrograph of a piece of hair-like sliver generated in a production line

Microstructure difference between aluminum and steel sheets. Aluminum sheets contain appreciable amount of constituent particles.

Schematic of the trends of cutting angle effects for aluminum and steel sheets

(a) Morphology of the third type sliver, as indicated by the arrows. Note that the picture background is the adhesive cellophane tape. (b) Two pieces of third type slivers still attached to the cut surface of a “part.”

Clearance, blade sharpness and cutting angle are parameters considered

Sliver damaged aluminum hood outer panels

Schematic of the trends of clearance effects with optimal cutting angles for aluminum and steel sheets

Schematic trimming configurations of the conventional (above) and the new (below)

Optical micrographs of the first type sliver: (a) the smooth and shiny surface side, (b) the rough surface side. Note that the picture background is the adhesive cellophane tape.

Scanning Electron Microscope (SEM) micrograph of the rough fracture surface of a first type sliver

Sketch illustrating the “part” and the “scrap” of a trimmed sheet

Two pieces of first type slivers barely hanging-on the edge of a “scrap.” The micrograph views from the top-down direction, as shown schematically. The smooth and shiny surface of the slivers resulted from contact with blade.

Schematic of the trends of blade sharpness effects with optimal cutting angles for aluminum and steel sheets

Two pieces of first type slivers barely hanging-on the edge of a “scrap.” The micrograph views from the bottom-up direction, as shown schematically. The rough surface of the slivers is fracture surface.

Scanning Electron Microscope (SEM) micrograph of the fracture surface of a first type sliver hanging-on the edge of a “scrap.”

Optical micrograph of the cross-section (as-polished) of an interrupted test specimen showing a C-shaped crack formed in the sheet. The dark area was occupied by the blade. The light area is the sheet material being trimmed half-way.

Optical micrographs of a second type sliver: (a) generated in the lab, (b) generated in a production line. Note that the picture background is the adhesive cellophane tape.

Origins of the second type sliver: cutting blade interaction with the secondary burnish area of the cut surface on a “part.” The micrograph views the cut surface from the direction as schematically shown. A second type sliver still attached to the secondary burnish area.

Origins of the second type sliver: cutting blade rubbing-off from the burr area of the cut surface on a “part.” The micrograph views the cut surface from the direction as schematically shown. Two pieces of second type sliver still attached to the burr area.

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