Numerical and Experimental Study on Guillotine Shearing of a Complex Profile Produced by Roll Forming process

One of the important sections of cold roll forming lines is the shearing of profiles, which is usually performed as the guillotine shearing for open profiles. Despite the importance of shearing quality on the assemblability of the open profiles, few researches have been done on their shearing operation. In this paper, the guillotine shearing of a complex open profile, door frame, was investigated. For this purpose, the guillotine shearing of this profile was simulated in Abaqus software and the effects of the important process parameters on the shearing quality were determined. In the experiments, the profiles were initially annealed to remove residual stresses produced during deformation and then were sheared. The experimental and finite element–predicted shearing cross-section were compared and the shearing defects were analyzed. The comparison revealed a good agreement and confirmed the finite element model. The results showed the increase of the shearing angle and the clearance between dies and profile reduces the shearing quality. In addition, the increase of the clearance between dies and profile and the clearance between dies reduces the shearing force. Finally, the best shearing conditions were proposed based on the results.