Blanking is a shearing process where a punch and die are used to create a blank from sheet metal or a plate. The blank is workpiece ejected from the starting stock. The process and machinery are usually the same as that used in piercing, except that the piece being punched out in the piercing process is scrap.
Simple blanking operations utilize pancake dies.
Fine blanking is a specialized form of blanking where there is no fracture zone when shearing. This is achieved by compressing the whole part and then an upper and lower punch extract the blank.This allows the process to hold very tight tolerances, and perhaps eliminate secondary operations.
Materials that can be fine blanked include aluminium, brass, copper, and carbon, alloy and stainless steels.
Fine blanking presses are similar to other metal stamping presses, but they have a few critical additional parts. A typical compound fine blanking press includes a hardened die punch (male), the hardened blanking die (female), and a guide plate of similar shape/size to the blanking die. The guide plate is the first applied to the material, impinging the material with a sharp protrusion or stinger around the perimeter of the die opening.
Next a counter pressure is applied opposite the punch, and finally the die punch forces the material through the die opening. Since the guide plate holds the material so tightly, and since the counter pressure is applied, the material is cut in a manner more like extrusion than typical punching.
Mechanical properties of the cut benefit similarly with a hardened layer at the cut edge from the cold working of the part. Because the material is so tightly held and controlled in this setup, part flatness remains very true, distortion is nearly eliminated, and edge burr is minimal.
Clearances between the die and punch are generally around 1% of the cut material thickness, which typically varies between 0.5–13 mm (0.020–0.51 in). Currently parts as thick as 19 mm (0.75 in) can be cut using fine blanking.Tolerances between ±0.0003–0.002 in (0.0076–0.051 mm) are possible based on material thickness & tensile strength, and part layout.
With standard compound fine blanking processes, multiple parts can often be completed in a single operation. Parts can be pierced, partially pierced, offset (up to 75°), embossed, or coined, often in a single operation. Some combinations may require progressive fine blanking operations, in which multiple operations are performed at the same pressing station.
Advantages & disadvantages
The advantages of fine blanking are:
excellent dimensional control, accuracy, and repeatability through a production run.
excellent part flatness is retained.
straight, superior finished edges to other metal stamping processes.
smaller holes possible relative to thickness of material.
little need to machine details.
multiple features can be added simultaneously in 1 operation.
more economical for large production runs than traditional operations when additional
machining cost and time are factored in (1000–20000 parts minimum, depending on secondary machining operations)
The disadvantages are:
slightly higher tooling cost when compared to traditional punching operations.
slightly slower than traditional punching operations.
Blanking is a metal fabricating process, during which a metal workpiece is removed from the primary metal strip or sheet when it is punched. The material that is removed is the new metal workpiece or blank.
Characteristics of the blanking process include:
Its ability to produce economical metal workpieces in both strip and sheet metal during medium or high production processes. / The removal of the workpiece from the primary metal stock as a punch enters a die.
The production of a burnished and sheared section on the cut edge. / The production of burred edges. / The control of the quality by the punch and die clearance. / The ability to produce holes of varying shapes – quickly.
The blanking process forces a metal punch into a die that shears the part from the larger primary metal strip or sheet. A die cut edge normally has four attributes. These include:
burnish / burr / fracture /roll-over
Blanking has many benefits, but manufacturers must take some considerations into account before embarking on a full course of metal blanking. Although this process is a quick and cost-effective way to produce a large number of identical pieces, these punched-out pieces may have burrs or cracks on the edges. However, these drawbacks can be avoided by using high-quality tools, and they can be corrected by post-processing the blanks.
Blanking is a metal fabricating process, during which a metal workpiece is removed from the primary metal strip or sheet when it is punched. The material that is removed is the new metal workpiece or blank.
Characteristics of the blanking process include:
Its ability to produce economical metal workpieces in both strip and sheet metal during medium or high production processes,
The removal of the workpiece from the primary metal stock as a punch enters a die,
The production of a burnished and sheared section on the cut edge,
The production of burred edges,
The control of the quality by the punch and die clearance,
The ability to produce holes of varying shapes – quickly.
The blanking process forces a metal punch into a die that shears the part from the larger primary metal strip or sheet. A die cut edge normally has four attributes. These include:
burnish
burr
fracture
roll-over
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