Abstract
In this study, numerical modeling and experimental tests of the sheet metal cutting process were carried out in order to determine the shape of the cutting knives for a roller shear, ensuring the minimization of burr on the cut edge. A rolling mill was used for the tests, enabling the replication of the cutting process in a roller shear (demonstrating the possibility of using cutting rollers). The cutting edges of the sheets were examined using light microscopy and then compared with the results of numerical simulations to determine the cutting quality. The tests were performed for multiphase Complex Phase (CP) grade steel. The initial thicknesses of sheets were equal to 1 and 2 mm. Based on the results of theoretical research, four shapes of cutting rollers were designed, of which two shapes were selected for experimental tests. The analysis of the test results shows that the lowest burr values were obtained for straight and beveled rollers. Analyzing the size of burr obtained in experimental tests, it can be concluded that for each of the two variants of the roller shape, a reduction in burr was achieved. Greater reductions in burr were achieved for shaped (cut) rolls.