Influence of Blade Profile of Disc Cutter on Numerical Simulation of The Disc Slitting Process

The disc slitting machining experiments for electrical steel sheet were conducted to investigate the wear process of carbide alloy disc cutter and the slitting quality in the disc slitting process, and the blade contour shape of disc cutter in different slitting distance was measured by the surface profiler. A DEFORM-2D model, where the real blade profile or arc fitting profile was used as the blade contour of the cutter, was built to simulate the disc slitting process. Results show that the blade wear of disc cutter increases. The blade wear presents uneven in the side surface and cylindrical surface of the cutter, and the side wear is more serious with the increase of the slitting distance of electrical steel sheet. As the blade wear increases, the height of the rollover increases gradually, the height of the shear area increases at first and then decreases, but the height of the fracture area decreases at first and then increases. Compared with the arc fitting profile, the simulation surface morphology using the real blade profile is in good agreement with the experimental result. The variation of blade profile can change the distribution of the hydrostatic stress of sheet metal and the occurring and propagating of the crack, and the maximum hydrostatic stress can be used to estimate the change tendency of the fracture area.