3D modeling of shear-slitting process for aluminum alloys

This work combines experimental studies with finite element simulations to develop a reliable numerical model for simulating the important shearing process in aluminum alloys. Burr formation in shearing is of critical concern with respect to the quality of the product. The paper discusses various aspects leading to the modeling of the shearing process with an aim to design process parameters for burr reduction. Three damage models are implemented in the finite element model for simulating the shearing process. Experiments with macroscopic and microscopic observations are used to characterize the material quantitatively and to calibrate the constitutive and damage models. The user material subroutine VUMAT is used for implementation of material and damage models in the commercial finite element code ABAQUS. Parametric studies are finally conducted to study the effect of process parameters on the shearing process and especially on burr formation.