Amorphous Alloy Foil Shearing with Stress-Relieved Punch Geometry
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Solution Overview
Problem
Press-shearing of amorphous alloy foils is challenging due to their high strength and low ductility, leading to issues with tool life and machining quality, such as tool breakage and cracks in punched parts.
Innovation Solution
A punch with a cutting edge having a specific functional shape, characterized by optimized horizontal and vertical distances between edges, is used to suppress stress concentration and promote shear deformation over bending deformation, thereby improving tool life and machining quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional edge punch with 90-degree cutting edge angle is used, then sharpness and desired cut surface are obtained, but tool durability is insufficient and tool breakage occurs frequently
Solution Approach 1:
The invention changes the geometric parameters of the cutting edge by introducing a specific angle (α) between the cutting edge and the axis of the punch, and by defining specific dimensional relationships (lengths a and b) between different edges. This parameter optimization allows the punch to maintain sharpness while distributing stress more effectively, thereby extending tool life without sacrificing cut surface quality.
2Manufacturing precision
If the tool cutting edge is sharpened to concentrate shear stress, then shear droop and shear surface are formed improving quality, but tool life is reduced due to increased wear and breakage risk
Solution Approach 1:
The invention optimizes the geometric parameters of the cutting edge, specifically the angle α and the dimensional relationship between lengths a and b, to achieve a balance between stress concentration and tool durability. The optimized parameters enable sufficient shear stress concentration for quality cuts while distributing the load to prevent excessive wear and breakage.
3Productivity
If press-shearing is applied to amorphous alloy foils with high strength and low ductility, then productivity is improved, but tool breakage frequency increases and tool life shortens
Solution Approach 1:
The invention introduces optimized geometric parameters for the punch cutting edge, including a specific angle α and controlled dimensional relationships, that reduce the peak shear load required for cutting high-strength amorphous alloy foils. This parameter optimization maintains high productivity while extending tool life by reducing the mechanical burden on the tool.
4Manufacturing precision
If conventional punching is used on amorphous alloy foils, then cracks occur in punched parts due to low ductility, but modifying the punch shape to prevent cracks increases device complexity
Solution Approach 1:
The invention prevents cracks in punched parts by optimizing the geometric parameters of the punch cutting edge (angle α and dimensional relationship between a and b) rather than by adding complex structural modifications. This parameter-based approach maintains product quality while avoiding increased device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed solution enables efficient machining of amorphous alloy foils with improved tool durability and reduced occurrence of cracks and kink bands in the machined products, enhancing productivity and quality.
Implementation Method 1
how to concentrate the shear stress in the material to form a shear droop and a shear surface is important in ensuring the quality of the cut surface
Implementation Method 2
The shear droop and the shear surface are formed due to the plastic deformation of the material
Implementation Method 3
promote shear deformation over bending deformation
Data Source
AI summary
A method for shearing a plurality of layered amorphous alloy foils 28 includes blanking the plurality of amorphous alloy foils 28 with a shear tool having a punch 12 and a die 14 through one descending of the punch 12. The punch 12 has a first edge E1 formed on a tip surface 12a of the punch 12 and a second edge E2 formed on a side peripheral surface 12b of the punch 12. A horizontal distance l between the first edge E1 and the side peripheral surface 12b and a vertical distance h between the second edge E2 and the tip surface 12a are each set in a range of 0.010 mm to 0.050 mm. A vertical distance h is set to 52% or less of the thickness of each amorphous alloy foil 28.