Cutting force

Cutting force is the force which has to act on the stock material in order to cut out the
blank or slug. This determines the capacity of the press to be used for the particular
tool.
Caluculation of cutting force
Cutting force = l*s*T max
where, l = length of periphery to be cut in mm
s = sheet thickness in mm
T max = shear strength of stock material in N/mm square
Relationship between shearing action and cutting force
The three critical stages of shearing action are related to cutting force. Resistance
begins when the punch contacts the stock material. The load builds up rapidly during
the plastic deformation stage. It continues to increase while penetration takes place.
The accumulated load is suddenly released when fracture occurs. The curve levels off
near the bottom. The last portion of the load curve represents frictional resistance
developed.
- as the punch travels through the stock material
- as the blank or slug passing through the die.
If proper cutting clearance condition exists between the punch and the die fracture
will occur when cutting force equals the shear strength of the material.
Methods of reducing press force
In some cases it will be necessary to reduce cutting force to prevent press overloading.
A method to reduce press force is to grind the face of the horizontal plane. This
reduces the area of contact during shear at any one time.
Providing shear angle also reduces shock to the press and smoothens out the cutting
operation.
The shear angle should provide a change in punch length from 1 to 1.5 times the sheet
thickness.
Double shear angle is preferred over single shear angle because it does not create
lateral forces.
double shear angled punches should be concave to prevent stretching the material
before it is cut.
to prevent distortion on the stock material
- for blanking operation the shear angle will be on the die member.
- for piercing operation the shear angle will be on the punch member.
Another method to reduce cutting force is to step punch lengths. Punches or groups of
punches are made progressively shorter by about one sheet thickness.