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Shear dominated deformation with curved beaks in folding-shearing
Rishabh Arora1, Omer Music2, Julian M Allwood1
1Department of Engineering, University of Cambridge, Trumpington Street, Cambridge, CB2 1PZ UK.
The International Journal, Advanced Manufacturing Technology
|June 20, 2025
Summary
The folding-shearing process reduces automotive material waste. Optimizing the beak geometry with negative Gaussian curvature minimizes thickness variation, improving process robustness and reducing waste.
Area of Science:
- Manufacturing Engineering
- Materials Science
Background:
- Deep drawing in automotive manufacturing generates significant material waste (up to 45%).
- The folding-shearing process offers a solution for in-plane shearing with minimal thickness variation.
Purpose of the Study:
- To investigate the influence of beak geometry curvature on thickness distribution in folding-shearing.
- To develop an analytical model for predicting thickness changes and a design map for optimization.
Main Methods:
- Physical and numerical simulations were employed to analyze the folding-shearing process.
- An analytical model was developed to predict thickness distribution based on beak geometry.
Main Results:
- A beak design featuring negative Gaussian curvature reduced maximum thickening by 65%.
- The analytical model achieved an accuracy within 12.5% deviation compared to experimental results.
Conclusions:
- Optimizing beak geometry, specifically using negative Gaussian curvature, significantly enhances the folding-shearing process.
- The developed analytical model and design map enable efficient optimization for minimal thickness change and improved process robustness.
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