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Research Papers

Lateral Forces in Rolling-Cut Shearing and Their Consequences on Common Edge Defects

[+] Author and Article Information
Alexander Zeiler

Automation and Control Institute (ACIN),
TU Wien,
Vienna, Austria
e-mail: zeiler@acin.tuwien.ac.at

Andreas Steinboeck

Automation and Control Institute (ACIN),
TU Wien,
Vienna, Austria
e-mail: steinboeck@acin.tuwien.ac.at

Andreas Kugi

Automation and Control Institute (ACIN),
TU Wien,
Vienna, Austria
e-mail: kugi@acin.tuwien.ac.at

Martin Jochum

AG der Dillinger Hüttenwerke,
Dillingen, Germany
e-mail: martin.jochum@dillinger.biz

1Corresponding author.

Manuscript received March 26, 2018; final manuscript received December 11, 2018; published online February 27, 2019. Assoc. Editor: Yannis Korkolis.

J. Manuf. Sci. Eng 141(4), 041001 (Feb 27, 2019) (9 pages) Paper No: MANU-18-1185; doi: 10.1115/1.4042578 History: Received March 26, 2018; Accepted December 11, 2018

This paper deals with the detailed analysis of the lateral process forces in rolling-cut shearing of heavy steel plates and their impact on edge defects. Rolling-cut shearing is still the most common method of heavy-plate side trimming. However, this method can entail edge defects like uneven longitudinal shape as well as burr and fractures in the area of the cut-changeover (beginning and end of the periodical cuts). In the existing literature, neither the root cause of these edge defects nor their nexus with the upper blade trajectory (blade drive-kinematics) has been analyzed in detail. In this work, these issues will be explored based on the finite element method (FEM) simulations and measurements from an industrial plant. The complex interrelation between drive-kinematics, varying lateral force, unintended lateral motion of the upper blade, unintended variation of the blade clearance, and quality defects is analyzed. The variation of the lateral force is identified as the root cause of such quality defects and a physical explanation for variations of the lateral force is given. The detailed understanding of the shearing process serves as a solid basis for an optimization and re-design of the drive-kinematics in a future work. Measurements from an industrial plant and simulation results show good agreement and thus confirm the theory. The results are transferable to other rolling-cut trimming shears.

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Figures

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Fig. 1

The rolling-cut principle

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Fig. 2

The rolling-cut principle (top view)

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Fig. 3

Typical longitudinal shape of the sheared edge

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Fig. 4

(a) Comparison of edge section around the cut-changeover and (b) in-between the changeovers

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Fig. 6

Schematic illustration of the lateral guiding of the upper blade and the equivalent springs (top view)

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Fig. 7

Measured and simulated lateral displacement of the upper blade at the shearing point

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Fig. 8

Comparison of measured longitudinal edge shape and measured lateral upper blade motion

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Fig. 9

Simulated lateral cutting force acting on the upper blade

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Fig. 10

Simulated and semi-empirically calculated cutting force Fy

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Fig. 11

Shearing angle αs(t) for a plate thickness of 30 mm

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Fig. 12

Velocities, displacements, and forces per unit acting on the blade, the blank holder, and the plate: (a) plate with illustrated relevant contact area and sectional planes at zip1 and zip2, (b) sectional plane at zip1, and (c) sectional plane at zip2

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Fig. 13

Simulated normal and shearing component of the lateral force on the upper blade

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Fig. 14

Simulated lateral force on the blade when using the present kinematics, the present kinematics without scrap knife, and the full-circle disc blade

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Fig. 15

Vertical displacement of the scrap along the longitudinal z-direction

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Fig. 16

Vertical bending displacement of the scrap along the lateral direction (x-direction)

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