Abstract: The bar cutting machine is used to cut mild steel bar by using shearing operation. Shearing operation uses punch and die. A punch (or moving blade) is used to push the work piece against the die (or fixed blade), which is fixed. Usually the clearance between the two is 5 to 10% of the thickness of the material, but dependent on the material. Clearance is defined as the separation between the blades, measured at the point where the cutting action takes place and perpendicular to the direction of blade movement. This causes the material to experience highly localized shear stresses between the punch and die. The material will then fail when the punch has moved 15 to 60% the thickness of the material, because the shear stresses are greater than the shear strength of the material and the remainder of the material is torn. Two distinct sections can be seen on a sheared work piece, the first part being plastic deformation and the second being fractured. Because of normal in homogeneities in materials and inconsistencies in clearance between the punch and die, the shearing action does not occur in a uniform manner. The fracture will begin at the weakest point and progress to the next weakest point until the entire work piece has been sheared.
Keywords: Shearing operation, punch, die, cutting edge, pneumatic equipments.