Investigation on the influences of clearance and notch-sensitivity on a new type of metal-bar non-chip fine-cropping system

• A new non-chip fine-cropping system and working principle are introduced in detail.
• A three-dimensional FE simulation model is established on ABAQUS/explicit platform.
• The single factor and orthogonal test method are both applied.
• The influence of clearance and notch-sensitivity are respectively investigated.
• The comparisons are performed by combining DUCTCRT, ηη, εfεf and two new parameters ωDωD and DmeanDmean.

The aim of the present paper is to study the influences of the clearance and the notch-sensitivity on a new type of metal-bar non-chip fine-cropping system by combining the ductile damage initiation criterion, the fatigue crack propagation path analysis and the micrograph fractography observation. The single factor test method and the orthogonal test method are both applied to the numerical simulations and the corresponding non-chip fine-cropping experiments. The comparative numerical results show that the ductile damage initiation criterion is obviously influenced by the clearance and the notch geometric parameters. The corresponding cropping experiments are carried out and achieve a good agreement with the simulation results. And some other interesting results, which are useful for practical fine-cropping, are also obtained.