In recent years, increasing levels of precision of the cut surface characteristics in the cutting process of a metal die have become required not only for crack prevention but also for die roll prevention. The conventional shaving die is unlikely to be applied to achieve these requirements. As an innovative design, a novel modified shaving die with two steps of tapering, press and cut tapers, was designed and proposed in this research. The finite element method (FEM) was used to clarify the cutting mechanism and identify the effects of the process parameters and geometry of the shaving die of interest on the cut surface characteristics based on material flow and stress distribution analyses. The press taper limits the die roll formation on the sheared edge during the first stage of the cutting phase, and the cut taper prevents a new die roll from forming during the second stage of the cutting phase. The results showed that by using the novel modified shaving die, die roll formation could be reduced. Furthermore, by suitably selecting the process parameters and geometry of the shaving die, nearly zero die roll (nZDR) could be achieved. Laboratory experiments were carried out to validate the FEM simulation results. The FEM simulation results showed good agreement with the experimental results in terms of the cut surface characteristics and the cutting forces.

近年来，不仅在防止裂纹方面而且在防止模具辊方面都要求提高金属模具的切割过程中的切割表面特性的精度水平。传统的剃须模具不太可能用于实现这些要求。作为一项创新设计，本研究设计并提出了一种新颖的改进型剃须刀，该剃须刀具有渐缩，压榨和切锥两个步骤。基于材料流动和应力分布分析，使用有限元方法（FEM）阐明了切削机理，并确定了工艺参数和目标剃须模具的几何形状对切削表面特性的影响。压榨锥度在切割阶段的第一阶段限制了模切辊在剪切边缘上的形成，切割锥度可防止在切割阶段的第二阶段形成新的模具辊。结果表明，通过使用新颖的改进的剃刮模具，可以减少模具辊的形成。此外，通过适当地选择剃须模的工艺参数和几何形状，可以实现接近零的模辊（nZDR）。进行了实验室实验以验证有限元模拟结果。有限元模拟结果在切削表面特性和切削力方面与实验结果吻合良好。进行了实验室实验以验证有限元模拟结果。有限元模拟结果在切削表面特性和切削力方面与实验结果吻合良好。进行了实验室实验以验证有限元模拟结果。有限元模拟结果在切削表面特性和切削力方面与实验结果吻合良好。