Wedge Die and Punch Cutting for Corrosion-Resistant Cut Edges
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Solution Overview
Problem
Existing cutting methods for surface-treated materials, such as plated metal sheets, result in insufficient corrosion resistance at the cut end faces due to incomplete coverage of the plating layer, leading to potential red rust and increased equipment costs and complexity in processing.
Innovation Solution
A cutting method using a cutting tool with wedge-shaped die and punch components, where the front end angles and radii of the cutting parts are optimized to ensure the coating layer covers the cut end face, maintaining corrosion resistance while reducing stress on the tool and facilitating cutting of materials with varying strengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional shearing cutting is used on surface-treated materials, then cutting can be performed, but the coating layer is not continuously covered on the cut end face, resulting in poor corrosion resistance
Solution Approach 1:
The patent applies parameter changes by optimizing the front end radius (R) of the cutting tool within a specific range (0.05mm to 0.50mm) and controlling the front end angle (θ) between 30° to 90°. These parameter adjustments modify the stress distribution during cutting, enabling the coating layer to be continuously deformed and covered on the cut end face without rupture, thereby improving corrosion resistance while maintaining manufacturing precision.
Solution Approach 2:
The patent implements preliminary action by pre-designing the cutting tool geometry (front end radius and angle) before the cutting process. This preliminary configuration ensures that during cutting, the coating layer is progressively deformed and continuously covers the cut end face from the beginning of the cutting action, preventing exposure of the base metal and ensuring corrosion resistance is built into the process rather than added afterward.
2Reliability
If the front end radius is increased to improve coating coverage, then corrosion resistance improves, but tool stress and potential tool damage increase
Solution Approach 1:
The patent resolves this contradiction through parameter optimization by establishing a specific range for the front end radius (0.05mm to 0.50mm). Within this range, the radius is sufficient to deform and cover the coating layer continuously on the cut end face, improving corrosion resistance. Simultaneously, the radius remains small enough to avoid excessive stress concentration that would compromise tool strength, thus balancing both requirements.
3Productivity
If conventional cutting methods are used, then cutting speed is maintained, but the cut end face has exposed metallic material leading to red rust
Solution Approach 1:
The patent maintains cutting productivity by using optimized front end parameters (radius 0.05mm to 0.50mm, angle 30° to 90°) that enable efficient material removal. Simultaneously, these parameter changes ensure the coating layer is continuously deformed and covers the cut end face, preventing red rust formation. This achieves both high productivity and protection against harmful corrosion effects without requiring additional post-processing steps.
Data Source
AI summary
There is provided a cutting method for cutting a workpiece using a cutting tool comprising a die and a punch, including: arranging the workpiece between the die and the punch, and in a state in which a wedge-shaped first cutting part of the die and a wedge-shaped second cutting part of the punch are opposed, pushing the punch relatively to the die side to cut the workpiece; wherein: a front end angle θ1 of the first cutting part and a front end angle θ2 of the second cutting part are each 10° or more and 120° or less, and a front end radius R1 of the first cutting part and a front end radius R2 of the second cutting part are each 0.5% or more and 35.0% or less of a sheet thickness.