1.

Blank Design

a. Minimum Practical Section should never be less than material thickness

or .060". A minimum section must be one and one half times material
thickness for high shear strength material for the most practical stamping.
b. Radii on Blank Corners - Corners can be sharp if material thickness is 1/16" or
less - over 1/16 " allow corner radii (R) equal to 1/2 material thickness. See
illustration.
c. Practical Design For Economy Manufacture.

• W = .060 minimum for materials thinner than .060" wider if possible.

• W1 = Never less than material thickness, wider if possible.
• L = 5 x W is maximum depth, should be less if possible.
• L1 = 5 x W is maximum length, should be less if possible.

The above rules (a and b) apply for maximum economy. If followed, all blank
periphery can be included in the blanking die, eliminating secondary tooling and
operations.

2. Piercing Round Holes

To pierce holes with economical tools and operations, the hole diameter must not be
less than the sock thickness. If the hole diameter is less than the material thickness
(or less than .060") it usually must be drilled and deburred and each of these
operations is slower than punching.
Illustration "B" indicates a hole diameter with a tolerance of plus or minus .002". We
can pierce a hole within these limits on the punch side for approximately 25% to
30% of the material thickness as indicated in Illustration "C". The percent of
thickness varies with the shear strength of the materials.

On holes where a machine finish is required, they can be punched undersized,

redrilled and reamed to size as shown. (See Illustration "E".)

If the web (distance between the hole and edge of material) is a minimum of the
stock thickness, the hole can be punched which is less expensive than drilling and
deburring. (See Illustration D.)

A web that is less than the stock thickness will result in a bulge on the blank. Budge
conditions would increase progressively as the web decreases, until there would be a
complete break through. However, the bulge is hardly visible until the web is
reduced to less than 1/2 the stock thickness. These examples would also apply to a
web between holes. (See Illustration F.)

If a measurable bulge is not permitted, a drilling and deburring operation may be

necessary.

As a suggestion, if the web is too narrow, the profile of the blank could be changed
by adding an ear of sufficient dimensions and shape to eliminate the problem. (See
Illustration G.)
Another alternate suggestion would be to change the contour of the blank to include
the hole as a notch. (See Illustration H.) The notch could either be pierced or be
wide enough so it could be included in the blank without a piercing or notching
operation .(See Blank Design)

Caution: The addition of the word "thru" to any hole diameter, regardless of
tolerances, indicates the requirement of the hole to be reamed. Reaming and the
additional chamfer to remove burr add two extra operations to the cost of the part.

3.Definition of Punched Holes

Identification of these punched holes can provide the basis for determining the
inspection parameters.

Rollover is the natural consequence of:

1. The punching process.

2. The mechanical properties of the material being punched.
3. The die application of techniques employed.

4. Specification and Measurement of Punched Holes

A common practice exists in dimensioning punched holes.

General Purpose Holes

1. Dimension feature size limits only.

2. Feature size is to be measured only in the burnished land area.
3. Shape deviations within the feature size limits are permissible.

Special Purpose Holes

1. Dimension only those elements that affect part function.

2. When dimensioned:
a. Burnished land to be specified as minimum only.
 b. Burr height to be specified as maximum only.

5. Recommended Minimum Ratios of Punched Hole Diameters To Stock

Thickness

Limitations are established in common practice for most economical production.

Recommended ratios are applicable to all common metals.

P = Punched Hole Diameter (0.062 min. dia.)

T = Stock Thickness

Material Ultimate Tensile Strength (PSI) - Ratio P to T

32,000 - P = 1.0T
50,000 - P = 1.5T
95,000 - P = 2T

6. Piercing - Adjacent To Bends

Illustration "A" indicates that the minimum inside distance required from the edge of
a hole to a bend is 1-1/2 times the material thickness (T) plus the bend radius (R)

Otherwise, distortion will occur as indicated in Illustration "B" - or piercing after form
must be considered.

Illustration "C" indicates a similar condition to "A", except for openings with an edge
parallel to bend. In this case the following requirements apply for economical tooling
and production:
 • When "L" = up to 1" - 2T + R (minimum).
• When "L" = 1" to 2" - 2-1/2T + R (minimum).
• When "L" = 2" or more - 3T to 3-1/2T + R (minimum).

7. Definition and Limits of Extruded Holes

An extruded hole is formed by punching a smaller hole and then flanging the sides.

R = Outer radius
H = Flange height
D = Inner diameter
T = Material thickness
8. Specifications and Measurement of Formed Parts
Preferred dimensioning and points to measure:
L = Linear dimensions; corner radius
R = Radii;
R1 = Typical inside bend or
R2 = Radius in flat blank
T = Material thickness
2 - Typical examples - additional views as needed

9. Position of the Form

"A" illustrates a design that is not desirable for quality or economy. When the form is
inside the blank profile, as shown, the material must be torn through the stock
thickness and the bend radius. If the part is under stress, this tear will likely cause
fatigue failures. In addition, stock tooling cannot be adapted because the flat area
adjacent to the form must be held in position during forming, which means extra
tooling expense.

"B" illustrates a similar condition, but with the form just outside the blank profile. In
this case, the tear extends to the center of the required bend radius.
"C" and "D" illustrates a possible solution by changing the blank profile to provide
relief for the bend. Besides eliminating the chance of fatigue under stress, there is a
possibility of using stock 90 degree vee punches and dies. The results are better
quality and less expensive engineering charges.

If the relief notches in illustration "D" are wide enough compared to the material
thickness and shear strength, or are designed like the relief in illustration "E", they
can be included in the blanking operation for very little engineering cost and no
extra operation.

10. Height of Form

"A" illustrates a 90 degree bend with insufficient height (h) to form properly.

Consequently, stock must be added so the form is high enough (H), stock is then
cutoff, which means additional tooling and an additional operation.

If "h" is not high enough, the cutoff tool may not have sufficient strength to stand up
for a particular material or thickness. This may result in a higher cost secondary
operation such as milling.
Illustration "B" indicates how to determine the minimum inside height "H", which in
this case equals 2-1/2 times the material thickness (T) plus the required bend radius
(R).

The concept illustrated by "B" above is converted to a chart form below for your
convenience. These recommended minimum formed height dimensions are general
to cover most variables of design, size, material types, tempers and thicknesses but
which will permit the most economical tooling and production. Proper design, small
parts and easily formed material, such as Aluminum, Brass, Copper and Mild Steel
may be formed with a slightly lower minimum inside formed height (roughly 20%
less).

11.Edge Conditions of Formed Parts

1. "As Formed" - This is most common and is formed from a controlled size and
shape blank.

2. "Die Trimmed" - This is usually simple die trimming and parts have edges
similar to flat stampings.

3. "Hemmed Edge" - This is formed for smoothness and stiffness.

4. "Curled Edge" - This is formed for maximum stiffness and smoothness.

5. "Lance-Formed" - Edges are likely to have more burr than flat stampings.
12. Styles of Embossing

13. Specifications and Measurement of Embossed Parts

Preferred dimensioning and points to measure on embossed parts.

14. Recommended Limits of Embossed Parts

Limits for depths of embossments to minimize fracturing.

FLAT V-BENDS - L (MAX) = 3T*

OFFSETS - L (MAX) = R1 + R2**

* Reduce to 2T for commercial grades of steel, one-quarter hard tempers, and alloys
of aluminum.

** Reduce to .5(R1 + R2) for commercial grades of steel, one-quarter hard tempers,
and alloys of aluminum.
15.Specification and Characteristics of Drawn Parts

The specification should show the form of the part, state the material, specify
dimensions and condition of symmetry.

D1 or D2 (not both)
D3
R1
R2
T
L1
L2
R3

D1 = Inside diameter at a plane of intersection

D2 = Outside diameter at a plane of intersection
D3 = Flange diameter at a plane of intersection
H = Depth of draw
L = Linear dimension
R1 = Punch radius
R2 = Die radius
R3 = Corner radius
S = 'Earing' due to directional property of material
T = material thickness

16. Edge Condition of Drawn Parts

18.Surface and Characteristic Conditions of Drawn Shapes

18. Measurement and Limits of Flatness

Perfect flatness is that condition which exists when all points on a surface lie in the
same plane.

Flatness tolerance is the permissible distance between two parallel planes within
which all irregularities of a given surface must lie.

Parts may be measured in either unrestrained or restrained conditions.

(Recommended limits are applicable to parts measured in the unrestrained
condition.)

Bottom surface irregularities are illustrated.

Commonly used flatness tolerances for metal stamping are shown below.

Surface Length - Flatness Tolerances

From 0" to 1" - .005" T.I.R.
1" to 4" - .005/inch T.I.R.
Over 4" - .020" plus or minus .004/inch of additional length, T.I.R.

19. Dimensioning Practices for Turret Press

If there is a single area where the designer can accomplish the greatest benefit in
producibility and economy of manufacture, it is perhaps in communicating effectively
with the supplier, using appropriate detailing practices on drawings. Following are a
few basic guidelines which can make an enormous difference:

First, select a meaningful datum in the body of the part - passing through hole
center, if possible - rather than using an edge or corner of the part. (See
dimensioning Practices for Press brake). There are several reasons for this
suggestion.

It avoids problems of possible misalignment of the part, distortion from clamping, etc.
It allows for more precise measurement by avoiding measurements from edges
which may be tapered and therefore dimensionally uncertain. It facilitates accurate
inspection and it avoids unnecessary accumulation of tolerances.
Second, on related hole patterns, dimensioning and tolerances should be within this
pattern with only one dimension linking to the general datum. Better quality control
and function of the product can be expected.

Third, highlight the truly significant dimensions. Critical dimensional relationships can
be protected, if they are known.

20. Dimensioning Practices for Press Brake

Practical experience has proven that dimensioning and measuring practices must
both be understood and agreed on by all parties to achieve a workable, mutual
standard. Formed sheet metal parts present a unique problem in that angular
tolerances as well as the flatness conditions interact with single plane dimensions
because of the flexibility of sheet metal, especially the thinner guages. To achieve
consistent results when measuring formed parts, a standard has to be established on
where and how dimensions are to be taken.

• Form dimensions should be measured immediately adjacent to the bend

radius in order not to include any angular and flatness discrepancy. See
illustration below.

• Feature-to-feature dimensions on formed legs of any length on flexible

parts will be assumed to be measured in constrained condition, holding the
part fixtured to the prints' angularity specification. This standard is
appropriate for the majority of thin sheet metal parts and results in a
functional product. This is always true when the assembled part is, by design,
held in constrained condition.

For most economical production, dimension the part in a single direction wherever
possible. Because of the sequential nature of the forming process, and the fact that
dimensional variation is introduced at each bend, dimensioning in a single direction
parallels the process and helps to control tolerance accumulation.
It is generally recommended that dimensioning be done from a feature to an edge.
Feature-to-feature dimensions in two planes should be avoided. Feature-to-bend
dimensions may require special fixtures or gauging.

This also means that tolerances in the title block of a drawing may be unnecessarily
restrictive for certain dimensions and angles, while very appropriate for others.

21. Laser Cutting

Current trend toward just-in-time (JIT) manufacturing, shorter part runs, and limited
product life cycles have increased the use of laser cutting machines in production
and prototype fabrication. Laser cutters are constantly evolving, as manufacturers
find new and innovative ways to apply this basic technology.

Often the capabilities of lasers and turret presses can be combined. Turret presses
are very fast and generate acceptable accuracy when punching many holes of the
same or different diameters. Lasers are particularly accurate and economical for
profiling irregular exterior contours.

These capabilities can be combined to produce accurate, complex parts at acceptable

production rates by using each machine to perform that part of the cutting operation
for which it is best qualified.

22. Laser Operation

Lasers can be operated in either the continuous wave (CW) or pulsed mode. CW
operation is faster and generates a smoother edge. It is inherently less accurate
because of thermal workpiece expansion due to the higher power levels reaching the
work.

Where there is a need for intricate or very close-tolerance cutting, the pulsed mode
generates less heat but produces a very finely serrated edge. The finest quality of
the workpiece is a carefully balanced compromise between speed, workpiece cooling
and edge condition.

Lasers are most productive when applied to mild steel and stainless steel and are
more difficult to employ on aluminum. Aluminum and certain other metals like zinc
and lead continue to reflect light when molten. This scatters the beam, requiring
more power. In addition, aluminum and copper alloys conduct heat away from the
cutting area which, again, requires more power.
23.Laser Considerations

In addition to production economics, precision and edge condition, the

knowledgeable designer considers these characteristics of laser produced parts when
designing for lasers.

• Localized Hardening. Lasers cut by melting or vaporizing metal. This can

create problems when cutting heat treatable materials as the area around the
part will become case hardened.

Laser cut holes in stainless steel or heat treatable steel alloys which require
machining (tapping, countersinking or reaming) can be particularly
troublesome. By the same token, designers can employ this characteristic to
their benefit when a product must be case hardened for wear resistance.

• Edge Taper. The laser is most accurate where the coherent light beam
enters the workpiece. As the beam penetrates the part, the light scatters
creating an edge taper condition similar but opposite from "breakout" in a
sheared or pierced part. (The hole on the side of the workpiece from which
the laser beam exits is generally smaller in diameter than on the entrance
side).

Thus the designer must carefully consider the final use of the part and, in
some cases, may have to specify from which side the part should be cut.

• Minimum Through-Feature Size. The cutting laser beam is focused down

to approximately 0.010 in. (0.2 mm) and is therefore capable of cutting holes
and features with radii approximating 0.030 in. (0.76 mm). The limits
applicable to piercing or blanking with a punch and die, such as the
relationship between features to avoid distortion, do not apply when laser
cutting.

However, some limitations do exit, and are also related to the material
thickness. See the illustration of the minimum through features which are
possible by laser. Laser cutting allows for through features to be 1/6th to
1/8th the size when compared to die piercing.

Also, since no mechanical force is applied, the width of material remaining

between cutout features may be very narrow without distortion occurring
during metal removal. A typical application would be tight spaced venting
slots on a visually important surface.
24. Laser Dimensioning Practices

It should also be recognized that the laser, like any other CNC servo driven machine,
accumulates mechanical, thermal and electromechanical tolerances during the
production cycle. For economy and quality, critical dimensions should be highlighted
and functional dimensions should be detailed in accordance with their function.

The use of material cutting lasers offers designers the ability to generate intricate,
close tolerance designs in materials which can be burned, melted, or vaporized.