Numerical Modelling and Simulation of the Shear-Slitting Process of Electrical Steels

Despite the development of laser processing, the mechanical cutting process is still widely used in the formation of electric steels that are very sensitive to thermal phenomena. However, proper process control is difficult due to the large number of factors determining the quality of the products. As a result, the quality of the cut edge is characterised by the presence of burrs, the removal of which increases the production costs. Due to their magnetic properties, these materials should not be exposed to excessive stresses and deformations. The article presents the possibilities of predicting the characteristic features of the cut edge as well as stress distributions in this area. Original shear-slitting finite element method (FEM) models were developed, the results of which were verified experimentally. The proposed method based on stress triaxiality analysis enables precise analysis of stress states in the cutting zone and the boundaries of the slip fracture transition in the separating fracture, as well as determining the method of material cracking. Variable control factors such as cutting clearance, rake angle of the upper knife, and cutting speed were taken into account in the models. Parametric analysis of the process was carried out and it was determined how the process parameters should be selected in order to obtain the appropriate quality of the product. The developed analysis results can be useful on production lines for proper process control.