Development of Simulation Strategies for the Application of Adiabatic Cutting in Sheet Metal Part Manufacturing in the Context of Materials Science

Funding: AiF/ FOSTA
Project: 18865 BG – P 1127
Contact:  Fabian Schmitz M. Sc.

Due to its high local rate of deformation ( ε̇ ≥103 s-1) and significant process time (t<2 ms ) adiabatic blanking exhibits temperature-induced softening (see figure a). This results in a high cutting quality and possible shortening of the process route in comparison to conventional blanking methods for advanced high-strength steels.

The resulting sheared surface exhibits special technological properties. This includes the geometry of the shear surface (see figure b) and the mechanical properties of the material (see figure c) in particular. The adiabatic effect occurs in a localized zone and, therefore, a fine meshing of the deformed area in FE-simulation is required in order to predict the accurate development of
the shear band. Advanced re-meshing strategies, e.g. adaptive re-meshing, are used. By this means, characteristics in the shear band such as temperature and strains (see figure d) are determined. The project is conducted in cooperation with the Institute of Materials Science and Engineering (LWW) in Chemnitz.

a) Thermal softening, b) Geometry of sheared surface, c) Hardness of ASB, d) Properties of ASB