Modelling of guillotining process of grain

oriented silicon steel using FEM

Cite as: AIP Conference Proceedings 2078, 020080 (2019); https://doi.org/10.1063/1.5092083
Published Online: 04 March 2019

Lukasz Bohdal, Leon Kukielka, Andrii M. Radchenko, Radoslaw Patyk, Marcin Kułakowski, and Jaroslaw
Chodór

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AIP Conference Proceedings 2078, 020080 (2019); https://doi.org/10.1063/1.5092083 2078, 020080

© 2019 Author(s).
 Modelling of Guillotining Process of Grain Oriented
Silicon Steel Using FEM
Lukasz Bohdal1, a), Leon Kukielka1, b), Andrii M. Radchenko2, c),
Radoslaw Patyk1, d), Marcin Kułakowski1, e) and Jaroslaw Chodór1, f)
1
Department of Mechanical Engineering, Koszalin University of Technology, Poland.
2
National University of Shipbuilding named after admiral Makarov, Ukraine.
a)
Corresponding author: lukasz.bohdal@tu.koszalin.pl
b)
leon.kukielka@tu.koszalin.pl
c)
andrad69@mail.ru
d)
radoslaw.patyk@tu.koszalin.pl
e)
marcin.kulakowski@tu.koszalin.pl
f)
jaroslaw.chodor@tu.koszalin.pl

Abstract. Magnetic materials are produced in large rolls that need to be cut to specific dimensions to make final
products. The high residual stresses, sheet deformation and burr formation at cut surface during the cutting process leads
to deterioration of magnetic properties of this materials. The paper focuses on the numerical and experimental analysis of
guillotining process using FEM. In computer models dynamic effects, mechanical coupling, constitutive damage law and
contact friction are taken into account. The effect of main process parameters on force characteristics, sheet deformation
and burr formation on cut surface of grain oriented silicone steel is analyzed. The results of computer simulations can be
used to forecasting quality of the final product.

INTRODUCTION
The guillotining process of sheet metals has been used often to prepare workpieces for subsequent forming
operations. The primary challenge in designing a guillotining process is to increase the durability of the tools,
efficiency of the process and the quality of the sheared edge, which are all affected by both the material properties
and the process parameters [1, 2, 3]. Grain oriented and non-oriented silicon steels are widely used to produce
laminations for electrical machines and transformers. The main difficulty at production lines during forming this
materials is the deteriorating effect of cutting on the magnetic properties of the material close to the cut edge. This is
a result of plastic deformations and concentration of stresses at this area. Some researchers analyzed the influence of
degraded area on magnetic properties of electrical steels. Pluta et al., [4] analyzed the magnetic properties of sheets
of electrical steel with different permeability, grain size and silicon content. TeNyenhuis et al., [5] analyzes the
effect of slitting grain-oriented electrical core steel on iron loss. Authors suggested that the cause of excessive
deterioration of magnetic properties during cutting is usually too high tension forces in shearing zone which
provides sheet deformation and grains separation.
The another problem of guillotining processes is deterioration of electrical steels cut surface quality by forming
of burrs and slivers which may include increasing the metal core eddy current loss and prevents the preparing of
sheet bundles. Knowledge of the mechanical cutting process of grain oriented and non-oriented silicon steels is
limited and based mainly on experimental methods, which are often unable to analysis of strongly nonlinear
phenomena occurring in the tools – material contact zones. Computational models using the finite element method
(FEM), are valuable in reducing the number of trial-and-error experiments required to predict the state of material
displacement, residual stresses, strains, material fracture, sheet deformations and quality of the sheared edge after

Computational Technologies in Engineering (TKI’2018)

AIP Conf. Proc. 2078, 020080-1–020080-7; https://doi.org/10.1063/1.5092083
Published by AIP Publishing. 978-0-7354-1806-6/$30.00

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cutting. Wisselink and Hu´etink [1, 2] developed a finite element model of guillotining of metal sheets to calculate
the steady state of such a process using the Arbitrary Lagrangian Eulerian formulation. Saanouni [6] coupled
Continuum Damage Mechanics with an FE model describing elasto-plastic behaviour to numerically simulate the
cutting of a metallic sheets. Gasiorek et al. [7] used FEM, ALE and SPH models to simulate cutting of multi-layered
aluminum sheets. Meehan and Burns [8] studied shear-slitting process using photoelastic micrographs and made
observations of the two-dimensional stress distributions. Aggarwal et al. [9] conducted a finite element analysis of
the magnetic tape slitting process. The polymeric tape substrate was modeled using a pressure dependent yield
function and material separation was incorporated using the shear failure criterion. Hubert et al. [10] developed a
strategy of numerical simulation which was used to study the effect of an edge-trimming parameter, the clearance,
on the steel specimen’s edges integrity after thickness reduction.
The aim of the present study is to develop and validate 3D FE model of the guillotining process of grain oriented
silicon steel which can be used in practical industry to analyzing the influence of conditions of the process on
physical phenomena which occur in the cutting process and quality of the workpiece. In computer models specific
cutting parameters for example: length of the shearing line, sheet dimension, tools geometry are taken into account.
This parameters are often omitted in FEM analysis of guillotining in literature. Developed model is validated with
experimental research by using guillotining test stand and vision-based solutions. The use of an advanced vision
systems to monitor of the cutting process of difficult to cut materials allows observing the phenomena of edge
bending, slivers and burrs formation. Using this system and FEM results is possible to develop of guidelines for the
correct selection of processing parameters. The effect of selected process technological parameters on the
mechanically affected zone and burr formation process on workpiece is analyzed.

FINITE ELEMENT MODELING

The description of the nonlinearity of the material is conducted using an incremental model that takes into
account the influence of the history of strains and strain rate. The object (the metal sheet that is being cut) is treated
as a body in which elastic strains may occur (in the scope of reversible strains) together with viscous and plastic
strains (in the scope of irreversible strains) with nonlinear strengthening. For the purpose of constructing the
material model, the following was used: Huber-Mises-Hencky’s nonlinear plasticity condition, the associated flow
law and combined strengthening (i.e., isotropic and kinematic). The state of the material after the aforementioned
processing is taken into account by introducing the following initial states: displacement, stresses, strains and their
rate. The states of strains and strain rate are described with nonlinear dependences and no linearization. In this
description, adequate measures are used for an increment of strains and for an increment of stresses (i.e., an
increment of Green-Lagrange strain tensor and an increment of the second symmetric stress tensor of Pioli-
Kirchhoff). The incremental contact model covers the contact forces, the contact rigidity, the contact boundary
conditions and the friction coefficients in this area. The mathematical model is supplemented with incremental
equations of the object’s motion and the uniqueness conditions. An incremental function of the total energy of the
system is introduced. From the stationary condition of this function, it is possible to derive a variational nonlinear
equation to describe the motion and deformation of the object for a typical incremental step [11, 12].
The tools (knives) are considered rigid bodies, but the sheet is modeled as the isotropic, elastic/visco-plastic
material with nonlinear hardening, the temporary yield stress of which is described with the aid of the Cowper–
Symonds model [13]:

[ ]
σ Y = 1 + (εi(P) / C ) (σ 0 + βEpε i(P) )
m
(1)

where β is the plastic strain hardening parameter, σ 0 is the initial, static yield point, εi(P) is the plastic strain rate
intensity, C is the material parameter defining the effect of the plastic strain rate intensity, m = 1/n is a material
constant defining its sensitivity to the plastic strain rate, ε i(P) is the plastic strain intensity and Ep = ETE / (E – ET) is the
material parameter depending on the modulus of plastic strain hardening ET = ∂σ Y / ∂ε i(P) and Young’s modulus E.
A discrete cracking approach is used in this study to model ductile fractures, and element deletion is adopted to
simulate crack propagation. A strain-based material separation criterion available in LS-DYNA is used in the
simulations developed [14]. According to the strain criterion, material separation occurs when the strain value of the
leading node is greater than or equal to a limiting value. As a result of experimental tests the limiting strain used is

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εf = 0.75 [15]. When an element of the matrix material reached the limiting strain value, the corresponding element
would be deleted.
Three-dimensional finite element model of guillotining is presented in Fig. 1. Numerical calculations are
performed for the 3D state of strain and 3D state of stress in this model. ET 122-30 (0.3 mm thick) grain oriented
silicon steel which is often employed for industry, is used to simulate typical production conditions. An element
with a length of l = 240 mm, width of wi = 90 mm is analyzed. The sheet is clamped by a sheet holder, and a rake
angle α is applied to the upper knive. The horizontal clearance c characterizes distance between tools along x axis.
The values of the Cowper-Symonds model constants for the ET-122-30 steel are taken as follows in this study: C =
= 40 s–1 and n = 5, β = 1 [15]. The objects are meshed with an 8-node Solid164 element type with reduced
integration and hourglass control, and the mapped mesh is generated with various sheet densities. The finite element
model of the sheet uses 840000 elements, that of the upper knife uses 48120 and that of the lower knife uses 22630.
The size of elements (where a is defined as element length, and h is defined as element height) in tools-sheet contact
zone is as follows: a = 0.015 mm, h = 0.015 mm. This size of elements allow for observation of flowing of material
and cracking with acceptable solution time (about 18 hours) (Fig. 2). This mesh density is selected so as to have a
reasonable number of elements at the thickness of the sheet. Larger elements dimensions not illustrate the material
flow features and stress distributions appropriately, and a smaller elements strongly increase the computing time.
The cutting tools are treated as non-deformable bodies, (rigid material model) E → ∞. A velocity of v = 250 mm/s
for the upper knive in the y direction is applied.
Zone 3: tools –
sheet contact
h zone

a Zone 1 Zone 2

Upper knive

α Rigid body characteristics

Sheet
y
z Blank-holder
x
Lower knive
c
FIGURE 1. Computer model of the guillotining process

The friction conditions between tools and the deformable sheet metal are described using Coulomb’s friction
model, and constant coefficients of static friction μs = 0.08 and kinetic friction μd = 0.01 are accepted. This friction
coefficients are typical for oil lubrication and are standard on industrial production lines. The LS-DYNA contact
model “surface to surface” is used in the analysis. The mechanical properties of the material are selected in Table 1.
TABLE 1. Mechanical properties
Density Silicon content Yield point Tensile strength Elongation Hardness
[kg/dm3] [%] [MPa] [MPa] [%] [HV5]
7.65 3,1 300 370 11 160

In the next section, we illustrate the present solution procedure’s capability to reproduce the effects of process
technological parameters such as the rake angle and clearance between knives on the quality of the sheet cutting
process.

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 a = 0,015 mm, h =0,015 mm
a = 0,1 mm, h =0,1 mm
(a) (b)

a = 0,015 mm, h =0,015 mm a = 0,1 mm, h =0,1 mm

(c) (d)
FIGURE 2. Influence of mesh density on plastic flow phase (a) and (b), cracking phase (c) and (d)

NUMERICAL AND EXPERIMENTAL RESULTS

Example of results are given in Figs. 3 and 4. During the guillotining process four main phases can be observed:
elastic, elastoplastic, elastoplastic in which damage occurs, initiation and propagation of cracks leading to final
separation [11]. At the start of the process, the knives indent the sheet, pulling down some surface material. This
causes the sheet to bend and creating the rollover and burnish zone at cut surface. As a result of the upper knive
movement when α = 4° the sheet is progressively cut from one end to the other (Figs. 3a and b). The highest stresses
can be observed at the tool - sheet cutting zone (Figs. 4a and b). The bending stresses increase with increasing rake
angle as the sheet is bent over a larger angle. Both the values and distribution of stresses change for increasing rake
angles because the tool-sheet contact zone becomes shorter for larger rake angles. In guillotining when α = 0° the
whole sheet is cut at one time and averaged maximum stresses from all time steps are higher than during cutting
when α = 4° is used.

(a) (b)
FIGURE 3. Equivalent stress distribution during guillotining when α = 4°: a) beginning phase, b) final phase

(a) (b)
FIGURE 4. Equivalent stress distribution during guillotining when α = 0°: a) beginning phase, b) final phase

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 Figure 5 shows the evolution of the guillotining force compared to the upper knive penetration. In guillotining
when α = 4°, only a portion of the sheet is cut at one time. Therefore, the stationary cutting force is independent of
the cut length. The cutting force depends mainly on the rake angle and sheet thickness for a given material, and an
increasing rake angle leads to lower forces over larger displacements. The peaks of force when α = 4° is a result of
fracture criterion used. When some mesh elements are deleted force values decreases. In case when α = 0° this
peaks are not visible becouse upper knive is in contact with sheet along full length of shearing line and during
fracture phase large number of FE elements are deleted.

(a) (b)
FIGURE 5. Evolution of the guillotining force versus upper knive displacement for the analysed rake angles: a) α = 4°, b) α = 0°

To detailed analysis of material flowing mechanism and cracking, stress and strain distribution at cross section of
the sheet during process a 2D numerical models are developed (Fig. 6). Numerical calculations are performed for the
2D state of strain and 3D state of stress in this model. ET 122-30 (0.3 mm thick) steel is analyzed. The objects are
meshed with an 4-node Solid164 element type. The sheet model consist of 48000 mesh elements. Tools are
modeled as a rigid bodies. Upper knive displacement is added at time step to obtain knive velocity of v = 250 mm/s.
The FE models are validated with using experiments and vision systems. Research with the use of an integrated
image registration system enables analysis of the large displacement process and deformation taking into account the
nonlinearity of the process. The use of vision techniques makes it possible to explain the physical phenomena
accompanying the cutting process.

Upper knive cracks

Flow area

Lower knive

(a) (b)
FIGURE 6. Image from high speed camera and equivalent strain distribution during plastic flow phase [Pa] (a),
image from high speed camera and equivalent strain distribution during cracking phase (b)

Figure 6a presents plastic flow phase of guillotining process recorded by high speed camera. The deformation
zone for this case is extended along the cross section of the sheet. The highest deformation both for numerical
results and experimental is concentrated at tools-sheet contact zones. Figure 6b presents cracking phase of
guillotining. In the cracking phase, it is possible to observe the extension of the plasticized area to the entire
thickness of the sheet. Crack propagation occurred after micro crack initiation from both upper and lower cutting
tools with the burr closely following the shape of the upper knive. Obtained results are in acceptable agreement with
obtained in 3D simulations in size of flowing area but during separation in 3D model cracking gap is wider as
a result of larger FE elements used in contact zones (Fig. 2c). Using FEM models and experiments a parametric

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analysis is done. The influence of rake angle α of the upper knive and horizontal clearance c between knives on burr
height on cut surface is analysed. The burr values (Figs. 7a and b) are measured from the simulations and
experiments using optical microscopy “Vision Engineering” at different locations over the cut edge in the
z-direction, averaged and compared. The numerical results are in satisfy agreement with those obtained from the
experiments, with an approximate error margin of 15% in burr height measurement. The differences arise form the
strong dynamics of the process and its nonlinarities, fracture criterion used, friction coefficients (constant in
simulations during the process) and mesh conditions. The minimum burr height can be obtained when values of
clearance in the range of (0.02–0.04 mm) and rake angle (α = 0–2°) are used. Increasing the clearance from
c = 0.02 mm to c = 0.1 mm significantly increases burr height at the given rake angles (Fig. 7b).

burr height hb [µm]

cut surface

hb

(a) (b)
FIGURE 7. Equivalent strain distribution at cut surface when c = 0.1 mm (a), the influence of rake angle
and clearance on burr height (experiment data) (b)

CONCLUSIONS
Mechanical cutting allows separating of sheet material at low cost and therefore remains the most popular way to
produce laminations for electrical machines and transformers. However, recent investigations revealed the
deteriorating effect of cutting on the magnetic properties of the material close to the cut edge. The deformations of
the sheet generate stresses and strain at cutting zone. This paper presents the methodology of modeling residual
stresses and strains induced in guillotining of grain oriented electrical steel. 2D and spatial 3D models taking into
account length of the shearing line were performed. Dynamic and damage effects, contact friction were accounted for in
the study. The effect of basis process technological parameters on guillotining process was investigated. Most trends
in the guillotining process are qualitatively well described by the developed model, which analyses the stress and strain
states at any moment during the process and identifies the causes of these defects in the metal sheets after processing
for example burrs and sheet deformation. In experimental study a new methods for visualization of technological
processes were used. Vision systems with using high speed cameras and image recording software allows for precision
observation physical phenomena occurring during the process for example flowing mechanisms of material and its
cracking. The simulation results could be used to provide residual stress fields, sheet deformation, flowing mechanism
and support the solution of practical problems.

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