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TECHNICAL PAPERS

Burr Height in Shear Slitting of Aluminum Webs

[+] Author and Article Information
Jin Ma, Bo Wang

School of Mechanical and Aerospace Engineering, Oklahoma State University, Stillwater, OK 74078

Hongbing Lu1

School of Mechanical and Aerospace Engineering, Oklahoma State University, Stillwater, OK 74078hongbin@ceat.okstate.edu

Ming Li

Process Mechanics, Applied Science Division, Alcoa Technical Center, Alcoa Center, PA 15069

1

To whom correspondence should be addressed.

J. Manuf. Sci. Eng 128(1), 46-55 (Mar 30, 2005) (10 pages) doi:10.1115/1.2123027 History: Received December 03, 2004; Revised March 30, 2005

Continuous shear slitting of aluminum sheets (or webs) was investigated using a laboratory slitter. This study focused on experimental investigation of the effect of three major slitting parameters (clearance, overlap, and cant angle) on the burr height. It was found that there exists a critical clearance in shear slitting of aluminum webs; using a clearance higher than the critical value leads to unacceptable burr height. The blade overlap must be within a certain range; using an overlap below the lower bound of this range will not enable the cut of a web, and utilizing an overlap higher than the upper bound of the range produces high burrs. A relatively large cant angle produces good slit edge quality but at the expense of the blade service life; a relatively small cant angle gives reasonable edge quality while maintaining a reasonable blade service life. Based on results on burr height for four aluminum webs, a relation linking the critical clearance to the slitting parameters and the web properties is presented. This can be used for selection of an appropriate clearance to produce good slit edge and low burr height for a given aluminum web.

Copyright © 2006 by American Society of Mechanical Engineers
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Figures

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Figure 1

Illustration of three sheet material related cuttings: (a) wrap shear slitting and (b) tangential shear slitting

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Figure 2

An SEM micrograph of a burr at a slit edge

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Figure 3

Sheet-metal shearing (trimming)

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Figure 4

Illustration of the parameters in shear slitting: (a) a driven-roller side view of the top and bottom blades, (b) a side view of the top and bottom blades, and (c) a top view of the blades

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Figure 5

Top blade holder

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Figure 6

Geometries of top and bottom blades

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Figure 7

Schematic of edge burrs relative to the blades

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Figure 8

Micrograph of slit edges. Web: 1050H18, 0.15mm thick; slitting conditions: cant angle=0deg, rake angle=0deg, overlap=0.50mm, speed=10.5m∕min, tension=10.3MPa

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Figure 9

Burr height variations along slit edges. Material: 1050, thickness=0.15mm, clearance=0mm, overlap=0.37mm, cant angle=0.5deg

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Figure 10

Average burr heights and standard deviations. Material: 1050, thickness=0.15mm, clearance=0mm, overlap=0.37mm, cant angle=0.5deg

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Figure 11

Effect of material and web thickness on the front bottom burr height. Cant angle=0.25deg, overlap=0.5mm

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Figure 12

Effect of cant angle and clearance on the front bottom burr height

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Figure 13

Effect of overlap and clearance on the front burr height

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Figure 14

Rear top burr height

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Figure 15

Six stages of the shear slitting process of 3004 web. Clearance=0mm, overlap=0.63mm, cant angle=1deg, tension=10.3MPa

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Figure 16

Slit edge surfaces of 3004 web: (a) illustration, (b) clearance=0.09mm, and (c) clearance=0.16mm; overlap=0.63mm, cant angle=1deg, tension=10.3MPa

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Figure 17

Relation of dimensionless parameters for all four webs

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