전단 각도가 올바르게 보이지만 스탬핑 안정성이 여전히 실패하는 경우

In many progressive die applications, shear angle is often treated as a secondary detail — mainly used to reduce cutting force or extend tool life.

But in real production, its impact goes much deeper.

There are cases where everything appears to be correct: material is consistent, press parameters are stable, and the die design follows standard practice. Yet the process still feels unstable. Edge quality fluctuates, tool wear appears uneven, and adjustments never fully “lock in” the process.

In these situations, the issue is often not the shear angle itself, but how it behaves across different stations.

Some punches may engage the material earlier due to their angle. Others may cut more flat, entering the material all at once. When this behavior is not consistent, the load no longer flows smoothly through the strip. Instead, it shifts.

This shift might be small, but its effects accumulate:

Over time, the process becomes difficult to predict.

Optimizing shear angle can help, but only if the geometry behaves consistently in real production conditions. Even small differences in angle execution or edge transition can change when the cut actually begins.

In the end, shear angle is not just about reducing force.
It directly affects how the load enters the system — and whether the process remains stable.

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