Abstract Edge quality produced by shearing processes often leads to reduced material formability which was observed in multiple studies and summarized in the reference literature. The intention to make the sheared edge performance more predictable has motivated the development of several experimental techniques such as the hole expansion test and the tensile test with one side of the sample sheared in various cutting conditions. The paper presents a review of published results for both of these techniques and illustrates very limited research dedicated to sheared edge performance of aluminum alloys. The experimental study was performed on three broadly used in automotive industry 6xxx serious aluminum alloys which have similar mechanical properties and chemical composition with some variation in processing regimes and individual elements quantities. The effects of cutting clearance on longitudinal, transverse and diagonal orientations of the trim line relative to the rolling direction were discussed for all three alloys. The results of standard tensile test of all three materials were very similar with rather small difference in work hardening and almost no difference in total elongations measured by an extensometer. Measurements of elongations as a result of stretching of samples along orthogonally trimmed sheared surfaces indicated that the increase of the cutting clearance above 5% for Alloy 1 and above 15% for Alloy 2 usually leads to formation of burrs and reduced elongations of trimmed samples before fracture occurs. The effect of cutting clearance on sheared edge stretching performance for Alloy 3 is significantly less pronounced than for Alloys 1 and 2, which makes Alloy 3 very attractive for exterior panel automotive applications in which significant stretching of sheared edge can be anticipated. Detailed discussion of mechanism of blank separation during trimming process was based upon the results of 2D numerical simulation and interrupted trimming process with partially propagated cracks.

中文翻译：

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汽车 6xxx 铝合金的修边和剪切边缘拉伸性

摘要 剪切过程产生的边缘质量通常会导致材料成形性降低，这在多项研究中观察到并在参考文献中进行了总结。使剪切边缘性能更可预测的意图推动了几种实验技术的发展，例如扩孔测试和拉伸测试，其中样品的一侧在各种切削条件下被剪切。该论文对这两种技术的已发表结果进行了回顾，并说明了专门针对铝合金剪切边缘性能的非常有限的研究。对汽车工业中广泛使用的三种 6xxx 严重铝合金进行了实验研究，这些铝合金具有相似的机械性能和化学成分，但在加工方式和单个元素数量上有一些变化。讨论了所有三种合金的切削间隙对纵切线相对于轧制方向的纵向、横向和对角线取向的影响。所有三种材料的标准拉伸试验结果非常相似，加工硬化差异很小，引伸计测量的总伸长率几乎没有差异。沿正交切边剪切面拉伸试样的伸长率测量结果表明，合金 1 的切削间隙增加 5% 以上和合金 2 的切削间隙增加 15% 以上通常会导致毛刺的形成和切边试样断裂前的伸长率降低发生。切削间隙对合金 3 剪切边缘拉伸性能的影响明显不如合金 1 和合金 2，这使得合金 3 对预计剪切边缘显着拉伸的外板汽车应用非常有吸引力。切边过程中毛坯分离机制的详细讨论是基于二维数值模拟和部分扩展裂纹的间断切边过程的结果。