On the Influence of Different Parameters on the Characteristic Cutting Surface when Shear Cutting Aluminum

Within this research, the sliver occurrence is physically motivated and a relation to the characteristic cutting surface appearance is established, in particular the clean-shear and the burr are of main interest. A detailed sensitivity analysis of various shear cutting process parameters is part of this study. Experiments are conducted for a full-edged shear cutting process along an open cutting line for a 6xxx aluminum alloy. The influencing parameters are studied in detail in order to enable an optimized process parameter configuration for the investigated material. For the evaluation of the conducted experiments, part and process characteristics are considered to ensure a holistic examination of the induced changes due to the varying process parameters. Therefore, besides an analysis of the material hardness in the sheared zone and the occurring cutting forces and their parameter-dependent variation, cutting surface characteristics are determined by tactile measurement.