Achieving pure shear deformation with curved beaks in folding-shearing

Achieving pure shear deformation with curved beaks in folding-shearing | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Achieving pure shear deformation with curved beaks in folding-shearing Rishabh Arora, Omer Music, Julian M. Allwood This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6213075/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 11 Jun, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract The deep drawing process in the automotive industry generates up to 45% of material waste. To address this issue, the folding-shearing process was developed as a drop-in solution, enabling the formation of parts in pure shear with minimal thickness variation. This process involves folding a blank while collecting the excess material in a region called the ‘beak’, which is subsequently sheared in-plane using a single set of tools in one forming direction. In previous work, the beak has had flat faces, which can lead to workpiece thickening and tool wear. This paper investigates the extent to which the beak geometry can be modified to minimise the thickening, focussing on a curved beak geometry. Numerical simulations, validated using physical trials, demonstrate that introducing a negative gaussian curvature in the deformation zone reduces the maximum thickening by 65%. An analytical model is developed to predict thickness in folding-shearing, achieving 12.5% accuracy compared to physical trials. Ultimately, a design map is proposed to instantly identify the optimal beak design parameters, without the need for extensive numerical or physical validations while ensuring a minimal thickness change. Sheet metal forming Folding-Shearing Stamping Design optimization Tool geometry Full Text Cite Share Download PDF Status: Published Journal Publication published 11 Jun, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Major Revisions Needed 06 May, 2025 Reviewers agreed at journal 23 Mar, 2025 Reviewers invited by journal 23 Mar, 2025 Editor assigned by journal 20 Mar, 2025 First submitted to journal 19 Mar, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6213075","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":432781619,"identity":"622aeb45-f193-4bb1-8295-94017a3ea730","order_by":0,"name":"Rishabh Arora","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Rishabh","middleName":"","lastName":"Arora","suffix":""},{"id":432781620,"identity":"24643371-c198-4894-a6d8-e29a53c32d54","order_by":1,"name":"Omer Music","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Omer","middleName":"","lastName":"Music","suffix":""},{"id":432781621,"identity":"edcc8685-10c0-434b-975c-8f2af27a1922","order_by":2,"name":"Julian M. 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To address this issue, the folding-shearing process was developed as a drop-in solution, enabling the formation of parts in pure shear with minimal thickness variation. This process involves folding a blank while collecting the excess material in a region called the \u0026lsquo;beak\u0026rsquo;, which is subsequently sheared in-plane using a single set of tools in one forming direction. In previous work, the beak has had flat faces, which can lead to workpiece thickening and tool wear. This paper investigates the extent to which the beak geometry can be modified to minimise the thickening, focussing on a curved beak geometry. Numerical simulations, validated using physical trials, demonstrate that introducing a negative gaussian curvature in the deformation zone reduces the maximum thickening by 65%. An analytical model is developed to predict thickness in folding-shearing, achieving 12.5% accuracy compared to physical trials. Ultimately, a design map is proposed to instantly identify the optimal beak design parameters, without the need for extensive numerical or physical validations while ensuring a minimal thickness change.\u003c/p\u003e","manuscriptTitle":"Achieving pure shear deformation with curved beaks in folding-shearing","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-04-01 07:13:10","doi":"10.21203/rs.3.rs-6213075/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Major Revisions Needed","date":"2025-05-06T10:19:42+00:00","index":"","fulltext":""},{"type":"reviewerAgreed","content":"","date":"2025-03-24T01:38:52+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-03-23T19:56:59+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-03-20T04:50:06+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2025-03-19T11:30:40+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"8d33e59b-f037-4502-a723-6e5c9a8cb64b","owner":[],"postedDate":"April 1st, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"published-in-journal","subjectAreas":[],"tags":[],"updatedAt":"2025-06-16T16:01:31+00:00","versionOfRecord":{"articleIdentity":"rs-6213075","link":"https://doi.org/10.1007/s00170-025-15853-9","journal":{"identity":"the-international-journal-of-advanced-manufacturing-technology","isVorOnly":false,"title":"The International Journal of Advanced Manufacturing Technology"},"publishedOn":"2025-06-11 15:57:37","publishedOnDateReadable":"June 11th, 2025"},"versionCreatedAt":"2025-04-01 07:13:10","video":"","vorDoi":"10.1007/s00170-025-15853-9","vorDoiUrl":"https://doi.org/10.1007/s00170-025-15853-9","workflowStages":[]},"version":"v1","identity":"rs-6213075","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-6213075","identity":"rs-6213075","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}