DFM Of Fine-blanked Parts Introduction NTTF

Chapter 1
Fine-Blanking Process

CH1. FINE BLANKING PROCESS 1

DFM Of Fine-blanked Parts Introduction NTTF

Why Fine-Blanking?

CH1. FINE BLANKING PROCESS 2

DFM Of Fine-blanked Parts Introduction NTTF

Why Fine-Blanking?
•Where the side edge of pressing needs to
work as a functional surface
•Side edge surface ~ 100% sheared

?
CH1. FINE BLANKING PROCESS 3
What is Fine Blanking?
•The process called fine blanking uses special
presses and tooling to produce flat components from
sheet metal or plate, with high dimensional accuracy

•According to Hydrel A.G., Romanshorn, Switzerland,

fine-blanking presses can be powered hydraulically or
mechanically, or by a combination of these methods,
but they must have three separate and distinct
movements

•These movements serve to clamp the work material,

to perform the blanking operation, and to eject the
finished part from the toolBLANKING PROCESS
CH1. FINE 4
What is Fine Blanking?
•Forces of 1.5–2.5 times those used in conventional
stamping are needed for fine blanking, so machines
and tools must be designed and constructed
accordingly

•In mechanical fine-blanking presses the clamping and

ejection
... forces are exerted hydraulically.

•Such presses generally are of toggle type design and

are limited to total forces of up to about 280 tons.

•Higher forces generally require all-hydraulic designs.

These presses are CH1.
also suited to embossing,
FINE BLANKING PROCESS
coining,
5
and impact extrusion work.
DFM Of Fine-blanked Parts NTTF

CH1. FINE BLANKING PROCESS 6

 4 3
2

Please draw
in sequence
of numbering

6? 6
5?
1
CH1. FINE BLANKING PROCESS 7
Fine-blanking Process NTTF

Stage 1

Material fed into the die

CH1. FINE BLANKING PROCESS 8

Fine-blanking Process NTTF

Stage 2

Upstroking ram lifts lower table & die set

CH1. FINE BLANKING PROCESS 9

 Stage 3
Counterpunch
Die Plate

•As tool closes, V ring is embedded

in material
•Material is clamped between
“Stinger” plate & die plate outside
shear periphery
V-Ring
•Counterpunch clamps the material
? against blanking punch face inside
Blanking
shear periphery
Punch CH1. FINE BLANKING PROCESS 10
Fine-blanking Process NTTF

Stage 4

•Punch continues Upstroking

•Cleanly shearing part into die & inner-form slug
into punch
•At TDC all pressures are shut off
CH1. FINE BLANKING PROCESS 11
Fine-blanking Process NTTF

Stage 5

•Ram retracts
•Die opens
CH1. FINE BLANKING PROCESS 12
Fine-blanking Process NTTF

Stage 6

•V-Ring pressure is reapplied

•Strips punch from skeleton material
•Pushes inner-form slug up out of punch
•Material feed begins
CH1. FINE BLANKING PROCESS 13
Fine-blanking Process NTTF

Stage 7

•Counterpressure reimposed
•Ejects part from die
CH1. FINE BLANKING PROCESS 14
Fine-blanking Process NTTF

Stage 8

Part & slug removed from die area by air /

removal arm

CH1. FINE BLANKING PROCESS 15

Fine-blanking Process NTTF

Stage 9

•Cycle is complete
•Ready to recommence
•Same as stage 1
CH1. FINE BLANKING PROCESS 16
Fine-blanking Process NTTF

CH1. FINE BLANKING PROCESS 17

Fine-blanking Process NTTF

CH1. FINE BLANKING PROCESS 18

Blanking Vs Fine-Blanking

CH1. FINE BLANKING PROCESS 19

Fine-blanking Process NTTF

Comparison of Write down

Conventional Blanking Versus appropriate
Fine-Blanking answers

Blanking
# Particulars
Conventional Fine
1 Press Mechanical Hydraulic; Triple
Action Special
Purpose Press

CH1. FINE BLANKING PROCESS 20

Fine-blanking Process NTTF

Comparison of
Conventional Blanking Versus 1.5 - 2.0?
Fine-Blanking

Blanking
# Particulars
Conventional Fine
1 Press Mechanical Hydraulic; Triple
Action Special
Purpose Press

CH1. FINE BLANKING PROCESS 21

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
2 Press Tool Conventional Purpose Built
design of special
construction
having high
Precision

CH1. FINE BLANKING PROCESS 22

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
2 Press Tool Conventional Purpose Built
design of special
construction
having high
Precision

CH1. FINE BLANKING PROCESS 23

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
3 Components May or may Ready for
not be ready assembly
for assembly

CH1. FINE BLANKING PROCESS 24

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
3 Components May or may Ready for
not be ready assembly
for assembly

CH1. FINE BLANKING PROCESS 25

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
4 % of cleanly ~33% ~100%
sheared
surface
over
material
thickness

CH1. FINE BLANKING PROCESS 26

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
4 % of cleanly ~33% ~100%
sheared
surface
over
material
thickness

CH1. FINE BLANKING PROCESS 27

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Occurrence
of Fracture
5 Yes No
during
Blanking

CH1. FINE BLANKING PROCESS 28

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Occurrence
of Fracture
5 Yes No
during
Blanking

CH1. FINE BLANKING PROCESS 29

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Secondary
Shaving /
operations
Milling /
required to
Reaming /
6 make the NIL
Broaching /
sheared
Hobbing /
surface
Grinding
functional

CH1. FINE BLANKING PROCESS 30

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Secondary
Shaving /
operations
Milling /
required to
Reaming /
6 make the NIL
Broaching /
sheared
Hobbing /
surface
Grinding
functional

CH1. FINE BLANKING PROCESS 31

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Dimensional
7 IT 10 - 14 IT 7 –10
Accuracy

CH1. FINE BLANKING PROCESS 32

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Dimensional
7 IT 10 - 14 IT 7 –10
Accuracy

CH1. FINE BLANKING PROCESS 33

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Punch-die
8 Clearance ~5% t 0.5% t
as % ‘t’

CH1. FINE BLANKING PROCESS 34

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Punch-die
8 Clearance ~5% t 0.5% t
as % ‘t’

CH1. FINE BLANKING PROCESS 35

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Punch
9 enters the Yes No
die

CH1. FINE BLANKING PROCESS 36

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Punch
9 enters the Yes No
die

CH1. FINE BLANKING PROCESS 37

Fine-blanking Process NTTF

Blanking
S.No Particulars
Conventional Fine
Squareness
10 of sheared - 50”
surface

CH1. FINE BLANKING PROCESS 38

Fine-blanking Process NTTF

Blanking
S.No Particulars
Conventional Fine
Squareness
10 of sheared - 50”
surface

CH1. FINE BLANKING PROCESS 39

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
V-Ring Pressure
Pressure
11 Blanking Shearing Pressure
Applied
Counter Pressure

CH1. FINE BLANKING PROCESS 40

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
V-Ring Pressure
Pressure
11 Blanking Shearing Pressure
Applied
Counter Pressure

CH1. FINE BLANKING PROCESS 41

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Accuracy of
12 shut height ~ mm 0.01mm
setting

CH1. FINE BLANKING PROCESS 42

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Accuracy of
12 shut height ~ mm 0.01mm
setting

CH1. FINE BLANKING PROCESS 43

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Shearing
13 5-15mm/s
speed

CH1. FINE BLANKING PROCESS 44

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Shearing
13 5-15mm/s
speed

CH1. FINE BLANKING PROCESS 45

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
14 Flatness ? Superior

CH1. FINE BLANKING PROCESS 46

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
14 Flatness ? Superior

CH1. FINE BLANKING PROCESS 47

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Surface 0.8
15 ?
Finish Ra (0.2-0.4)

Relationship between Micron & Micro”?

CH1. FINE BLANKING PROCESS 48

Fine-blanking Process NTTF

Blanking
# Particulars
Conventional Fine
Surface 0.8
15 ?
Finish Ra (0.2-0.4)

Relationship between Micron & Micro”?

CH1. FINE BLANKING PROCESS 49

Fine-blanking Process NTTF

CHARACTERISTICS OF
FINE BLANKING

S.No FEATURE PARTICULARS

1 Three 1. Constant Shearing
Actions of Pressure
Press 2. Constant V Ring Pressure
3. Constant Counter Pressure

CH1. FINE BLANKING PROCESS 50

Fine-blanking Process NTTF

CHARACTERISTICS OF
FINE BLANKING

S.No FEATURE PARTICULARS

1 Three 1. Constant Shearing
Actions of Pressure
Press 2. Constant V Ring Pressure
3. Constant Counter Pressure

CH1. FINE BLANKING PROCESS 51

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

2 Shearing Slower 4 –15 mm / Sec
Speed

CH1. FINE BLANKING PROCESS 52

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

2 Shearing Slower 4 –15 mm / Sec
Speed

CH1. FINE BLANKING PROCESS 53

Fine-blanking Process NTTF

S.No Feature Particulars

3 Ram Stroke + / - 0.01mm
Adjustment
Accuracy

CH1. FINE BLANKING PROCESS 54

Fine-blanking Process NTTF

S.No Feature Particulars

3 Ram Stroke + / - 0.01mm
Adjustment
Accuracy

CH1. FINE BLANKING PROCESS 55

Fine-blanking Process NTTF

4 Preferred Compound Tool

die Design Progressive Die also possible
(e.g; Chamfering Int. / Ext
 Bending Leg
 Offset
 Protrusion
 Coining for Counter-bore
 Thin down Material
 Form shallow draws)

CH1. FINE BLANKING PROCESS 56

Fine-blanking Process NTTF

4 Preferred Compound Tool

die Design Progressive Die also possible
(e.g; Chamfering Int. / Ext
 Bending Leg
 Offset
 Protrusion
 Coining for Counter-bore
 Thin down Material
 Form shallow draws)

CH1. FINE BLANKING PROCESS 57

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

5 Examples of  Sprockets
Typical Parts  Gears
produced  Gear Segments
 Ratchets
 Racks

CH1. FINE BLANKING PROCESS 58

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

5 Examples of  Sprockets
Typical Parts  Gears
produced  Gear Segments
 Ratchets
 Racks

CH1. FINE BLANKING PROCESS 59

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

6 Finish ~0.8 Ra
Obtainable ~0.2 – 0.4 Ra with Carbide
on the side dies
surface

CH1. FINE BLANKING PROCESS 60

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

6 Finish ~0.8 Ra
Obtainable ~0.2 – 0.4 Ra with Carbide
on the side dies
surface

CH1. FINE BLANKING PROCESS 61

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

7 Typical 0.8 – 8.0 mm

Thickness
Range
blanked

CH1. FINE BLANKING PROCESS 62

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

7 Typical 0.8 – 8.0 mm

Thickness
Range
blanked

CH1. FINE BLANKING PROCESS 63

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

8 Die Roll / ~30%t max
Pull down /
Blanking
Droop

CH1. FINE BLANKING PROCESS 64

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

8 Die Roll / ~30%t max
Pull down /
Blanking
Droop

CH1. FINE BLANKING PROCESS 65

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

9 Burr Slight

CH1. FINE BLANKING PROCESS 66

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

9 Burr Slight

CH1. FINE BLANKING PROCESS 67

Fine-blanking Process NTTF

10 Outside Provide V ring on the die side

Chamfer of part in a preceding station
of the die exactly at the
location where the blanked
outer edge will be. Blanking
will part the V Ring impression
thus producing a chamfer on
the die roll side of part. We
can get upto 30% t chamfer
S.No FEATURE PARTICULARS
CH1. FINE BLANKING PROCESS 68
Fine-blanking Process NTTF

10 Outside Provide V ring on the die side

Chamfer of part in a preceding station
of the die exactly at the
location where the blanked
outer edge will be. Blanking
will part the V Ring impression
thus producing a chamfer on
the die roll side of part. We
can get upto 30% t chamfer
S.No FEATURE PARTICULARS
CH1. FINE BLANKING PROCESS 69
Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

11 Offset <75 deg possible

CH1. FINE BLANKING PROCESS 70

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

11 Offset <75 deg possible

CH1. FINE BLANKING PROCESS 71

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S.No FEATURE PARTICULARS

12 Semi- Possible upto 70% t
Piercing

CH1. FINE BLANKING PROCESS 72

CH1. FINE BLANKING PROCESS 73
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S.No FEATURE PARTICULARS

12 Semi- Possible upto 70% t
Piercing

CH1. FINE BLANKING PROCESS 74

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

13 Economic >20,000
Production
Quantity

CH1. FINE BLANKING PROCESS 75

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

13 Economic >20,000
Production
Quantity

CH1. FINE BLANKING PROCESS 76

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

14 Structural Cold Rolled Spheroidized –
Requirement Annealed ( Good dispersion of
of Steel small cementite spheres
within a soft ferrite matrix)
Tensile Strength 260 – 520
MPa

CH1. FINE BLANKING PROCESS 77

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

14 Structural Cold Rolled Spheroidized –
Requirement Annealed ( Good dispersion of
of Steel small cementite spheres
within a soft ferrite matrix)
Tensile Strength 260 – 520
MPa

CH1. FINE BLANKING PROCESS 78

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

15 Other  Hard Grade Al T5-T6 with
Materials some edge fracture
that can be  Lead free Brass
blanked  Copper(with Lubricant to
avoid build up due to cold
weld)

CH1. FINE BLANKING PROCESS 79

Fine-blanking Process NTTF

S.No FEATURE PARTICULARS

15 Other  Hard Grade Al T5-T6 with
Materials some edge fracture
that can be  Lead free Brass
blanked  Copper(with Lubricant to
avoid build up due to cold
weld)

CH1. FINE BLANKING PROCESS 80

Thank You
CH1. FINE BLANKING PROCESS 81