Name: Mohamed Saeed Sayed

Department: Mechanical Major: Production

Section: 4
Supervision: Professor Doctor engineer / Hussein abd al moniem

Die Design
 Abstract

It's well known that one of the main operations of the sheet metal processes
is the cutting operation and one the main die groups is cutting dies and as a
main method of achieving cutting process is the shearing process that is only
another name of the cutting process; which is applying a shear stress on the
metal causing it to plastic deform then starts to fail giving the required shape
of cut weather it's a blanking or piercing and through the next pages we will be
discussing the conditions required for this shearing process and how can it be
achieved and graphically how it can be applied.
The shearing process is performed on a shear machine, often called a squaring shear or power shear, that can be
operated manually (by hand or foot) or by hydraulic, pneumatic, or electric power. A typical shear machine includes a
table with support arms to hold the sheet, stops or guides to secure the sheet, upper and lower straight-edge blades, and
a gauging device to precisely position the sheet. The sheet is placed between the upper and lower blade, which are then
forced together against the sheet, cutting the material. In most devices, the lower blade remains stationary while the
upper blade is forced downward.

Thus there is various types of the blades of this machine or the type of fixing the work piece:

- Straight parallel cutters

- Straight inclined cutters
- Rotary cutters

There are various conditions affecting the cut the shape of it and how to achieve it; the force applied by the cutters,
the clearance between cutters and work piece, the surface finish of the work piece the condition of cutters both parts of
bunch and die.

First calculating the force:

The zone we are trying to achieve is after the plastic deformation so the force applied must be higher than the maximum
shearing stress of the material causing the material to fail while giving the required cut but is reached through multiple
phases giving the required force and cut , as if the force is less than the yield strength it will only be elastically deformed
while if it was more than the UTS it will be plastically deformed

Stages of shearing operation

Different Types of shearing cutters:
This cutting procedure can be done through different shapes of cutters each has its own shape angle and product
depending on the type of cut you need and also the Strength of material as each type can also give different amount of
force and can affect the thickness differently.

- Straight inclined cutters:

Used for cutting material of relatively small thickness compared the the width of cutting
using inclined cutters to reduce the shearing force and give the needed range of motion to
disjoin the material.

- Straight parallel cutters:

The calculated shearing force needs to be increased
depending on:
Obtuseness of the angle.
Enlarged clearance between cutters.
Variations in thickness of the material.

- Rotary Cutters
This type of cutter is much similar to straight inclined cutters because the
straight cutter can be considered as a rotary cutter but with an infinite
radius but here we can produce rotary cuts and irregular shapes.

Another two cutting operation similar to shearing are

blanking and piercing which are also used in cutting sheet
metal but into an exact shape the major difference is in the
scrap or the removed and used metal part.