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Shear dominated deformation with curved beaks in folding–shearing.

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Title: Shear dominated deformation with curved beaks in folding–shearing.
Authors: Arora, Rishabh1 (AUTHOR), Music, Omer2 (AUTHOR), Allwood, Julian M.1 (AUTHOR) allwood-office@eng.cam.ac.uk
Source: International Journal of Advanced Manufacturing Technology. Jun2025, Vol. 138 Issue 11, p5959-5978. 20p.
Subjects: Metal stamping, Map design, Metalwork, Shear (Mechanics), Sheet metal
Abstract: The deep drawing process in the automotive industry generates up to 45% material waste. To address this issue, the folding–shearing process was developed as a drop-in solution, enabling the formation of parts in pure shear with minimal thickness variation. This process involves folding a blank while collecting the excess material in a region called the 'beak', which is subsequently sheared in-plane using a single set of tools moving in one forming direction. This paper investigates the extent to which the curvature of the geometry of the beak influences the resulting thickness distribution. A combination of physical and numerical trials demonstrates that a beak design with a negative Gaussian curvature reduces the maximum thickening by 65%. This reduction in thickening helps minimise the forming loads and tool wear, thereby improving the overall robustness of the process. An analytical model is proposed to predict the resulting thickness distribution and demonstrates accuracy within a 12.5% deviation from experimental results. Finally, a design map is proposed to instantly identify the optimal beak design parameters without the need for extensive numerical or physical validations while ensuring a minimal thickness change. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Shear dominated deformation with curved beaks in folding–shearing.
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  Data: <searchLink fieldCode="AR" term="%22Arora%2C+Rishabh%22">Arora, Rishabh</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Music%2C+Omer%22">Music, Omer</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Allwood%2C+Julian+M%2E%22">Allwood, Julian M.</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> allwood-office@eng.cam.ac.uk</i>
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  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Advanced+Manufacturing+Technology%22">International Journal of Advanced Manufacturing Technology</searchLink>. Jun2025, Vol. 138 Issue 11, p5959-5978. 20p.
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  Data: <searchLink fieldCode="DE" term="%22Metal+stamping%22">Metal stamping</searchLink><br /><searchLink fieldCode="DE" term="%22Map+design%22">Map design</searchLink><br /><searchLink fieldCode="DE" term="%22Metalwork%22">Metalwork</searchLink><br /><searchLink fieldCode="DE" term="%22Shear+%28Mechanics%29%22">Shear (Mechanics)</searchLink><br /><searchLink fieldCode="DE" term="%22Sheet+metal%22">Sheet metal</searchLink>
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  Label: Abstract
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  Data: The deep drawing process in the automotive industry generates up to 45% material waste. To address this issue, the folding–shearing process was developed as a drop-in solution, enabling the formation of parts in pure shear with minimal thickness variation. This process involves folding a blank while collecting the excess material in a region called the 'beak', which is subsequently sheared in-plane using a single set of tools moving in one forming direction. This paper investigates the extent to which the curvature of the geometry of the beak influences the resulting thickness distribution. A combination of physical and numerical trials demonstrates that a beak design with a negative Gaussian curvature reduces the maximum thickening by 65%. This reduction in thickening helps minimise the forming loads and tool wear, thereby improving the overall robustness of the process. An analytical model is proposed to predict the resulting thickness distribution and demonstrates accuracy within a 12.5% deviation from experimental results. Finally, a design map is proposed to instantly identify the optimal beak design parameters without the need for extensive numerical or physical validations while ensuring a minimal thickness change. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1007/s00170-025-15853-9
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      – Code: eng
        Text: English
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        PageCount: 20
        StartPage: 5959
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      – SubjectFull: Metal stamping
        Type: general
      – SubjectFull: Map design
        Type: general
      – SubjectFull: Metalwork
        Type: general
      – SubjectFull: Shear (Mechanics)
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      – SubjectFull: Sheet metal
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      – TitleFull: Shear dominated deformation with curved beaks in folding–shearing.
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            NameFull: Music, Omer
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              M: 06
              Text: Jun2025
              Type: published
              Y: 2025
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