Analysis of Cutting Surface During Cutting of Electric Sheets
The contribution evaluates the influence of the size of the cutting gap on the quality of the cutting surface during the cutting process. Four types of electrical sheets were evaluated. Examined sheet types have the nominal thickness of 0.65 and 0.5 mm. Sheets differ in mechanical properties (yield...
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Інститут проблем міцності ім. Г.С. Писаренко НАН України
2017
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| Cite this: | Analysis of Cutting Surface During Cutting of Electric Sheets / E. Spišák, L. Kaščák, J. Majerníková, M. Džupon // Проблемы прочности. — 2017. — № 4. — С. 135-142. — Бібліогр.: 8 назв. — англ. |
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Digital Library of Periodicals of National Academy of Sciences of Ukraine| _version_ | 1860101827899424768 |
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| author | Spišák, E. Kaščák, L. Majerníková, J. Džupon, M. |
| author_facet | Spišák, E. Kaščák, L. Majerníková, J. Džupon, M. |
| citation_txt | Analysis of Cutting Surface During Cutting of Electric Sheets / E. Spišák, L. Kaščák, J. Majerníková, M. Džupon // Проблемы прочности. — 2017. — № 4. — С. 135-142. — Бібліогр.: 8 назв. — англ. |
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| description | The contribution evaluates the influence of the size of the cutting gap on the quality of the cutting surface during the cutting process. Four types of electrical sheets were evaluated. Examined sheet types have the nominal thickness of 0.65 and 0.5 mm. Sheets differ in mechanical properties (yield strength, ultimate tensile strength, and elongation). For the impact analysis, four values of the 0.02, 0.05, 0.1, and 0.2 mm cutting gap were used.
Анализируется влияние величины зазора резки на качество поверхности реза при обработке резанием. Исследовались четыре типа электротехнических листов с номинальной толщиной 0,65 и 0,5 мм и различными механическими характеристиками (предел текучести, предел прочности при растяжении и относительное удлинение). Для анализа влияния указанных факторов использовались четыре значения зазора резки: 0,02; 0,05; 0,1 и 0,2 мм.
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UDC 539.4
Analysis of Cutting Surface During Cutting of Electric Sheets
E. Spiðák,a,1 L. Kaðèák,a,2 J. Majerníková,a and M. Dþuponb
a Department of Mechanical Technologies and Materials, Faculty of Mechanical Engineering,
Technical University of Koðice, Koðice, Slovakia
b Slovak Academy of Sciences, Institute of Materials Research, Koðice, Slovakia
1 emil.spisak@tuke.sk
2 lubos.kascak@tuke.sk
The contribution evaluates the influence of the size of the cutting gap on the quality of the cutting
surface during the cutting process. Four types of electrical sheets were evaluated. Examined sheet
types have the nominal thickness of 0.65 and 0.5 mm. Sheets differ in mechanical properties (yield
strength, ultimate tensile strength, and elongation). For the impact analysis, four values of the 0.02,
0.05, 0.1, and 0.2 mm cutting gap were used.
Keywords: electric sheets, cutting surface, cutting gap, hardening.
Introduction. From the process of shearing, it is known that the quality of the cutting
surface is highly influenced by the cutting gap, apart from the other parameters. Formation
of the cutting surface, with the cutting gaps at various sizes, is described in many articles
and related literature [1, 2]. Terms such as optimal cutting gap in terms of the minimization
of the shear force and optimal cutting gap in terms of the quality of the cutting gap [3–5]
often appear in the literature. The formed cutting surface can be generally characterized by
the areas of pressing (rounding), plastic cut, shear, and burr (Fig. 1). Ratios of these
individual parts made of the same materials change according to the size of the cutting gap
(Fig. 2). Formation of the cutting surface, with the cutting gap at various sizes, is presented in
Fig. 2.
© E. SPIÐÁK, L. KAÐÈÁK, J. MAJERNÍKOVÁ, M. DÞUPON, 2017
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2017, ¹ 4 135
Fig. 1. Cutting surface.
Fig. 2. Influence of the size of the cutting gap on the cutting surface.
In this contribution, we deal with the influence that cutting gaps at various sizes have
on the quality of the cutting surface during the cutting of electric sheets. These sheets were
chosen for the experimental research, because of the quality of the cutting edges and its
considerable influence on the effective use of wattage in all the rotating electrical machines
[2, 6].
In Fig. 3 we can see the influence of the size of the cutting gap on the shape of the
cutting surface during the process of punching and blanking. Figure 3a shows us the
optimal cutting gap in terms of the minimal shear force and Fig. 3b depicts the cutting
surface with the small cutting gap [3, 5].
Not only the quality of the cutting surface expressed by the individual zones but also
the change of the properties of the cut material in the area of cut (hardening of material) has
a considerable influence on the so-called watt losses of the rotating electrical machines [4,
7].
Due to the shape of the formed (cutting) surfaces after the cutting and the shape of the
hardening in the area of cut, it is necessary; in the case of most of the products, mainly
rotors and stators of the rotating electrical machines; to adjust the surfaces of the cut-outs
put together into bundles. Adjustments are realized by (chip) machining, most often by face
turning of the perimeter of a bundle.
However, it is an “additional” kind of operation and that is why there is an effort, for
the individual kinds of the qualities and thicknesses of electric sheets, to set the conditions
that would eliminate the operations of the (chip) machining and minimize the losses caused
by the low-quality cutting surface and the hardening in the area of cut.
E. Spiðák, L. Kaðèák, J. Majerníková, and M. Dþupon
136 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2017, ¹ 4
a
b
Fig. 3. Shape of the cutting surface with the large and the small cutting gap.
There are new methods proposed and presented in the contemporary literature and the
contributions. Methods of production of the rotor and stator laminations bound into the
bundles by plasma arc cutting, laser cutting and waterjet cutting [6–8]. Considering the
ability of the technology of laser cutting, or waterjet cutting, we must point out that even
though better properties can be achieved in terms of the surface in the area of cut, these
kinds of technologies can be used only in piece and batch production.
The speed of production of the rotor or stator bundle, while using above technologies,
cannot compete with the cutting process provided by the cutting tools. Contemporary
cutting tools are double-row and multi-row and apart from punching they enable binding
cut-outs into bundles, see the tool in Fig. 4.
Apart from the size of the cutting gap, deformation of the cut material during the
process of cutting has a considerable influence on the quality of the cutting surface as well.
The forces acting on the edges of punch and die during the process of cutting are shown in
Fig. 5. These forces and the moments of acting forces are dependent on the size of the
cutting gap, but also on the way a sheet is held down during the process of cutting [4, 5].
To prevent the deformation of the cut sheet, like the deformation shown in Fig. 5,
contemporary cutting tools for rotor and stator laminations are constructed the way that
guide plate, while it manages the tools (punches), has a spring-back and it also functions as
a blank holder.
1. Experimental Material. For this experimental research, we used the material of
nominal thickness 0.65 and 0.5 mm. Two types of the used materials differed in various
mechanical properties. We examined a cold rolled material and a material processed by
annealing. Mechanical properties and the production of used materials are shown in Table 1.
The chemical composition of the sheets is shown in Tables 2 and 3. Used materials
differed mainly by the content of silicon. In the case of DL/FL sheets, the content of Si was
0.601% and in the case of DH/FH material it was 2.453%.
In Fig. 6, there is a structure of the examined materials presented. Used materials after
annealing differ in grain size. In the case of the material FL it is the case of a fine grained
structure. Material FH features structure with a considerably larger grain.
To obtain strength and plastic properties of the examined materials, the tensile test
was performed on them. Materials after rolling and after annealing acted differently during
the tensile test. Records of the tensile test of the examined materials are presented in Fig. 7.
From the respective diagram it is obvious that the material after annealing had a
considerably higher elongation and a lower tensile strength.
Analysis of Cutting Surface ...
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2017, ¹ 4 137
Fig. 4. Double-row tool for the production of rotor and stator bundles.
Fig. 5. Shear forces and the moments acting during the process of cutting.
Fig. 4 Fig. 5
138 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2017, ¹ 4
T a b l e 1
Mechanical Properties of Tested Sheets (Average Values) and the Marking of Sheets
Material Thickness
(mm)
Material
processing
Direction
(deg)
Rp0 2. ,
MPa
Rm ,
MPa
A, %
DL 0.65 cold-rolled 0 838.3 840.9 1.5
90 925.2 959.2 1.9
FL 0.65 annealed 0 262.7 389.0 30.0
90 283.4 405.1 30.0
DH 0.50 cold-rolled 0 1076.2 1076.7 2.4
90 978.5 1063.0 2.0
FH 0.50 annealed 0 347.9 482.8 29.9
90 360.8 492.6 30.0
T a b l e 2
Chemical Composition of the DL/FL Electric Sheets (mass.%)
C Mn Si P S Ta N2 Cu Ni Cr
0.0053 0.241 0.601 0.123 0.0049 0.002 0.0015 0.014 0.01 0.031
As Ti V Zr Nb Mo B Ca Sn
0.001 0.001 0.002 0.002 0.002 0.002 0.0004 0.0003 0.005
T a b l e 3
Chemical Composition of the DH/FH Electric Sheets (mass.%)
C Mn Si P S Ta N2 Cu Ni Cr
0.0033 0.229 2.453 0.008 0.0027 0.355 0.0023 0.013 0.006 0.021
As Ti V Zr Nb Mo B Ca Sn Sb
0.001 0.003 0.001 0.003 0.002 0.002 0.0003 0.0002 0.005 0.058
a b
Fig. 6. Structure of the material after annealing: (a) FL (0.6 mass.% Si); (b) FH (2.45 mass.% Si).
E. Spiðák, L. Kaðèák, J. Majerníková, and M. Dþupon
2. Measured Results. To prove the influence of the cutting gap on the quality of the
cutting surface, four sizes of the cutting gaps were chosen, namely: 0.02, 0.05, 0.1, and
0.2 mm.
Quality of the cutting surface was measured by the ratio of the area of plastic cut to
the total material thickness. From the results, we can expressly state that in the case of the
smallest cutting gap, the area of plastic cut reached almost 100% of the material thickness.
With the increasing cutting gap, the ratio of the area of plastic cut to the total material
thickness gradually decreased. Shear stress in the cut area caused the pull-outs of the
ferritic grains in multiple cases. These phenomena can be observed in Figs. 8 and 9.
Hardening in the area of cutting surface was set by the nanoindentation measurement
on the thin sections perpendicular to the cutting edge. Nanoindenter Agilent G200 with the
Berkovich tip was used. The measurement was realized in the direction parallel with the
surface of a sheet and perpendicular to the surface of a sheet in the 9 parallel rows (X-1 to
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2017, ¹ 4 139
a
b
Fig. 7. Diagram of the tensile test of the examined materials: (a) FL (0.6 mass.% Si); (b) FH (2.45
mass.% Si).
Analysis of Cutting Surface ...
X-9), 45 micrometers from each other. In every row, there was the position data of the
imprint of the indenter measured from the edge of the cutting line (Fig. 10). The intensity
of hardening was expressed by the ratio of the nanoindentation hardness measured in the
specific point to the indentation hardness measured in the area distant from the area of cut
(Fig. 10). Parameters of the test: maximum indentation depth 2000 nm, dwell in the
maximum depth 10s.
From the measured results of microhardness in the area of cutting surface, we can
state that the largest values of hardening were measured out when the cutting gap was the
largest. With the cutting gap of 0.05 mm, the smallest values of hardening were measured
out. In terms of the distance from the area of cut, largest hardening was measured out with
the cutting gap of 0.02 mm. From this fact it is obvious that with the smallest cutting gap
the area of hardening in the area of cutting surface is the largest, even though the values of
140 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2017, ¹ 4
a b
Fig. 8. Material FH after rolling (a) and annealing (b).
a b
c d
Fig. 9. Cutting gaps: 0.2 (a), 0.1 (b), 0.05 (c), and 0.02 mm (d).
E. Spiðák, L. Kaðèák, J. Majerníková, and M. Dþupon
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2017, ¹ 4 141
a
b
c
d
Fig. 10. Measurement of the hardening around the area of cutting line for FH material, cutting gaps
0.2 mm (a), 0.1 mm (b), 0.05 mm (c), and 0.02 mm (d).
Analysis of Cutting Surface ...
hardness are not highest. During the cutting of steel sheets with the larger grain structure,
the smallest cutting gap corresponded to the grains being extracted.
Conclusions. This contribution evaluated the influence of the cutting gap size on the
quality of the cutting surface during cutting of the electric sheets. Four types of electric
sheets were evaluated. Experimental sheets varied in silicon content and processing
method. Used sheets possessed different mechanical properties. The nominal thickness of
examined sheets was 0.65 and 0.5 mm.
To prove the influence of the cutting gap on the quality of the cutting surface, 4 sizes
of cutting gap were chosen: 0.02, 0.05, 0.1, and 0.2 mm. Quality of cutting surface was
evaluated by the ratio of the area of plastic cut to the total thickness of the material. Results
show us that with the smallest cutting gap (0.02 mm), cutting surface is smooth and
perpendicular. There are visible extracted grains in the lower part of the cutting surface.
Quality of cutting surface during the cutting with the cutting gap of 0.2 mm is not
appropriate and it cannot be used during cutting.
Measurement of hardness in the area of cutting surface was also realized for the
examined materials. Highest values of hardening were measured out with the largest cutting
gap. The largest area of hardening was measured out with the smallest cutting gap.
From the results, we can understand that it is necessary to observe and control the size
of cutting gap and the quality of the cutting edges of a tool during the whole durability of
the cutting tool.
Acknowledgments. The authors are grateful to APVV for support of experimental
work under grant APVV-14-0834.
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Received 01. 09. 2017
142 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2017, ¹ 4
E. Spiðák, L. Kaðèák, J. Majerníková, and M. Dþupon
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/NLD (Gebruik deze instellingen om Adobe PDF-documenten te maken die zijn geoptimaliseerd voor prepress-afdrukken van hoge kwaliteit. De gemaakte PDF-documenten kunnen worden geopend met Acrobat en Adobe Reader 5.0 en hoger.)
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| id | nasplib_isofts_kiev_ua-123456789-173696 |
| institution | Digital Library of Periodicals of National Academy of Sciences of Ukraine |
| issn | 0556-171X |
| language | English |
| last_indexed | 2025-12-07T17:29:13Z |
| publishDate | 2017 |
| publisher | Інститут проблем міцності ім. Г.С. Писаренко НАН України |
| record_format | dspace |
| spelling | Spišák, E. Kaščák, L. Majerníková, J. Džupon, M. 2020-12-16T16:46:14Z 2020-12-16T16:46:14Z 2017 Analysis of Cutting Surface During Cutting of Electric Sheets / E. Spišák, L. Kaščák, J. Majerníková, M. Džupon // Проблемы прочности. — 2017. — № 4. — С. 135-142. — Бібліогр.: 8 назв. — англ. 0556-171X https://nasplib.isofts.kiev.ua/handle/123456789/173696 539.4 The contribution evaluates the influence of the size of the cutting gap on the quality of the cutting surface during the cutting process. Four types of electrical sheets were evaluated. Examined sheet types have the nominal thickness of 0.65 and 0.5 mm. Sheets differ in mechanical properties (yield strength, ultimate tensile strength, and elongation). For the impact analysis, four values of the 0.02, 0.05, 0.1, and 0.2 mm cutting gap were used. Анализируется влияние величины зазора резки на качество поверхности реза при обработке резанием. Исследовались четыре типа электротехнических листов с номинальной толщиной 0,65 и 0,5 мм и различными механическими характеристиками (предел текучести, предел прочности при растяжении и относительное удлинение). Для анализа влияния указанных факторов использовались четыре значения зазора резки: 0,02; 0,05; 0,1 и 0,2 мм. en Інститут проблем міцності ім. Г.С. Писаренко НАН України Проблемы прочности Научно-технический раздел Analysis of Cutting Surface During Cutting of Electric Sheets Анализ поверхности реза при резке электротехнических листов Article published earlier |
| spellingShingle | Analysis of Cutting Surface During Cutting of Electric Sheets Spišák, E. Kaščák, L. Majerníková, J. Džupon, M. Научно-технический раздел |
| title | Analysis of Cutting Surface During Cutting of Electric Sheets |
| title_alt | Анализ поверхности реза при резке электротехнических листов |
| title_full | Analysis of Cutting Surface During Cutting of Electric Sheets |
| title_fullStr | Analysis of Cutting Surface During Cutting of Electric Sheets |
| title_full_unstemmed | Analysis of Cutting Surface During Cutting of Electric Sheets |
| title_short | Analysis of Cutting Surface During Cutting of Electric Sheets |
| title_sort | analysis of cutting surface during cutting of electric sheets |
| topic | Научно-технический раздел |
| topic_facet | Научно-технический раздел |
| url | https://nasplib.isofts.kiev.ua/handle/123456789/173696 |
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