Fraunhofer Institute for Machine Tools and Forming Technology
Fraunhofer Institute for Machine Tools and Forming Technology

High-speed impact cutting

High speed impact cutting (HSIC) – a real alternative

The process parameter of cutting speed significantly influences the quality of the cutting surface. In high speed impact cutting (HSIC) the kinetic energy of the tool is almost entirely converted into cutting energy; and there is no heat loss into the process environment. This cutting process provokes the development of so-called shear bands that cause early shear failure in the sheet material. The following positive effects are generated by HSIC:

Reduction of component deformation, improvement of dimensional stability, minimum distance between parts (material savings), lubricant-free cutting, high-quality and nearly burr-free micro-structured cutting surfaces, high cycle times, automation feasible.

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  • Energetic comparison between various conventional shearing processes and HSIC
  • Creating calculation rules for HSIC
  • Development of active component coatings suitable for HSIC
  • Manufacturing of various steel components and nonferrous components
  • Punching of tubes and profiles without using dies
  • Cutting of tubes using “flying” internal die

  • Energy- and resource efficiency in shearing technology
  • Processing of high strength and super high strength materials, e. g. pre-tempered semi-finished products and trimming of press-hardened components
  • Saving reworking stages such as heat treatment of component and cleaning
  • Off-tool parts

Development of process chains

  • Market analysis
  • Investigation of process chains
  • Process optimization
  • Cost-benefit calculation
  • Development of manufacturing concepts
  • Planning and development of HSIC tools and plant technology

Development and evaluation of forming strategies

  • Market analysis
  • Feasibility studies
  • Technology development
  • Development of characteristic process values and optimal forming strategies
  • Benchmarking
  • Numerical simulation
  • Manufacturing of prototypes
  • Material characterization, particularly for HSIC
  • Component characterization

Machine technology

  • ADIA7® machine for high speed impact cutting (7 kJ, cutting speed up to 10 m/s)
  • ADIAFLEX® machine for high speed impact cutting 2x 1 kJ and 2x 2 kJ (cutting speed for each machine up to 10 m/s)
  • Test station for high speed impact cutting, energy capacity up to 250 J, (cutting speed up to 71 m/s)
  • Test station drop tower, energy capacity up to 1,600 J
  • Test station drop tower, energy capacity up to 20 kJ

Testing technology

  • High speed tensile testing machine Zwick-HTM 16020 (testing speed in tension and compression up to 20 m/s)