Separation process study of shaped rolled products using a new press with a wedge-hinged mechanism

Abstract This study focuses on the development and evaluation of a new press design for separating rolled metal products. The goal of this design is to increase energy efficiency, reduce cutting force, and improve workpiece geometric accuracy compared to traditional crank presses. A wedge-hinged mechanism with a concave wedge is proposed, enabling a hybrid cutting process combining shear and torsion. The arcuate path of the cutting knife creates a stress concentrator that initiates material fracture and minimizes plastic deformation. The proposed method reduced energy consumption by 26% during separating and decreased peak cutting force by 20%. The optimal geometric relationship for energy minimization was determined: the distance to the hinge fulcrum should be half the radius of the concave wedge. A high correlation between theoretical and experimental results (within 8%) was confirmed. Furthermore, it was found that the energy-force parameters are independent of the orientation of the rolled product, emphasizing the technological versatility of the process. The developed mechanism represents a promising solution for upgrading existing mechanical presses and designing new equipment in the mechanical engineering and railway industries. Implementation of this technology is expected to significantly reduce operating costs, increase equipment durability, and improve the quality of the final product.