Sheet metal cutting process modeling

In this study, using the Ansys-Expilicit Module the cutting surface of sheet metal were performed. Material, material thickness and clearance were used different. The materials were 2, 3, 4 mm Stainless Steel, DKP and Aluminum 1100. The clearance value was % 2, 3, 4, 5, 6, 7, 8, 9, 10 thickness. The effect of die clearance on roll over width, roll over depth, burnish zone, fracture zone and burr zone has been investigated in a finite element analysis by a rigid-plastic FEM code. The experimental results, in agreement with theoretical calculations and the literature. From the analysis, it was found that roll over width, depth and burr increase with increasing die clearance. Burnish zone and fracture zone decrease with increasing die clearance. The results were compared with literature studies.Key Words : Sheet metal, cutting surface prediction, cutting analysis