New Billet Cutting Process Combining Torsion and Shear Load to Reduce Droop Height

Abstract A novel cutting method that combines shearing and torsion was investigated. Shearing is a fast process that has high precision in term of cut length. However shape defects such as droop and burr occur. Droop and burr do not occur in a rod cut using torsion, but, controlling the location of the cut is difficult. As each of these processes can compensate for the other’s shortcomings, by combining them, the new cutting method benefits from the advantages of both processes. The aim of this study was to apply the new cutting method to produce a high-quality billet that has high precision in term of cut length without shape defects. To achieve this, an experimental apparatus that simultaneously subject a wire to shear load and torsion was developed. The effects of shear load and torsion on shape defects and cut location in billets were investigated to elucidate the characteristics of the new cutting method. When cutting the wire using torsion, it was found that the cut location was determined by the shear load. Moreover, droop did not occur when a concentrated small shear load was applied over a narrow area.