Shear Cutting of Aluminum, Zinc, and Tin at Increased Speeds

Abstract

The temperature and temperature evaluation during shear cutting, particularly at increased speeds, is crucial for understanding the material behavior during cutting, validating thermo mechanical material models used in the finite element method, and predicting the tool wear. In this study, we measured the punch force and temperature for EN AW 6082, zinc, and tin for punch speeds 0.12, 0.2, 0.4, and 0.6 m/s using a cutting clearance of 0.075 mm. The temperature is evaluated based on the thermoelectric voltages arising from the sheet metal and tool material based on the Seebeck effect. The results demonstrate that the sheet metal strongly influences the thermal response during shear cutting. Higher temperature maxima were generally observed to occur later than the force maximum, likely due to additional frictional heating beyond plastic deformation.