Punching and Blanking Process Final

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PUNCHING AND

BLANKING PROCESS
Presented By: Presented To:
Nilabrata Bera Dr. Biswanath Dolui
Anupam Halder
Introduction:

 Punching and blanking processes are sheet metal forming


processes.
 In these two processes a finite volume of metal from a
sheet is removed by using die and punch.
 The shape and size of the portion removed depends on
the geometry of die and punch.
 Also the operation cost and time depends on die and
punch design.
Application:

 Automobile industries.
 Aerospace industries.
 Kitchen appliances.
 Mass production of sheet metal components.
Cutting Tool & Job Material:

 The cutting tool(punch and die) are made of hardened


steel or tungsten carbide.
 The sheet metal to be machined is generally made of
aluminium, brass, copper, stainless steels.
 In some cases plastic is also used.
Difference:

 In the punching process the final product is the metal


sheet from which metal is removed.
 In blanking process the final product is the removed
portion from the sheet.
Punching Press:

 It is a type of machine press used to cut the material.


 Can be very simple and manually controlled or very
complex and CNC controlled.
Drive Type of Punch Presses:

 Flywheel Drive
 Mechanical Punch Press
 Hydraulic Punch Press
 Servo Direct Turret Punch Press
Different Zones of Blanked Part:

 Rollover Zone (Zr)


 Shear Zone (Zs)
 Fracture Zone (Zf)
 Burr Zone (Zb)
 Depth Of Crack Portion (Dcp)
 Secondary Shear
Process:

 The job is held by job holders to prevent distortion.


 A clearance is provided between the punch and die.
 Force is given on the job by the punching tool.
 A finite portion of metal is removed from the sheet.
Die diameter(d1)=d2+2c
d2-punch diameter, c-clearance
Deformation of Workpiece:

 The job bends and is pulled down by the punch


movement.
 The grains elongate at A,B & D.
 When the elongation reaches a limiting value , rupture
occurs.
Working Force:

 The maximum force required to create a complete


rupture is, Fmax=σf Co L (σf -true rupture stress, Co -
optimum clearance. L-length of cut).
 The maximum force required can be reduced by avoiding
the simultaneous failure of the total area.
 This is done by providing an angle to the punch edge.
 But the total energy requirement remains same.
Effective Clearance:

 The amount of clearance given is very important.


 As the velocity of propagation of fracture lines is very
high, they may miss each other without optimum
clearance.
 In optimum clearance, a clean edge is obtained.
 In case of too little or too large clearance, secondary
deformation takes place.
Stripping Force

 Two actions take place in the punching process-punching


and stripping.
 A stripping force develops due to spring back of the
punched material that holds the punch.
 This force is generally expressed as a percentage of the
force required to punch the hole.
 The value of stripping force is generally given by the
equation,
SF = 0.02 L * t( L-length of cut , t-thickness of material).
Process Variants:

Depending on the shape of the metal removed or process,


there are some special types of Blanking processes-
 Fine Blanking
 Notching
 Lancing
 Slitting
 Nibbling
 Trimming
Fine Blanking Process:
 A special type of blanking process.
 Fracture zone does not form while shearing.
 Very tight tolerance is achieved by this process.
 Aluminium , brass, copper ,stainless steels are the metals
that can be fine blanked.
Notching:

 In notching, material is removed from the side of a sheet


material.
Lancing:

 Lancing process makes partway through the metal


without producing any scrap.
Slitting:

 It is an operation to cut a coiled sheet metal lengthwise


to produce narrower strips.
Nibbling:

 In nibbling operation, complicated shapes are cut out from


a sheet metal by producing overlapping notches.
 Without using any special tools, a simple, round or
triangular punch is reciprocated at a fixed location.
 The sheet metal is guided to obtain the desired shape of
cut.
Trimming:

 Trimming process refers to the removal of excess material


in a flange or flash.
Advantages:

 Punching and blanking are quick processes.


 The slug produced may be reused or recycled(depending
on material).
 It is often the cheapest and most cost effective method
for medium to high volume of production.
 It can create multiple shaped holes or same shaped holes
very fast.
Disadvantages:

 Equipment and tooling costs are high.


 Often needs secondary finishing operations to smooth
out burrs along the bottom edge.
 Fine blanking process is a slow process.
Conclusion:

 Punching and blanking process is very cost effective


process.
 Though the initial equipments cost may be high but it is
very useful for mass production.
 Very closer dimensional tolerance can be achieved by fine
blanking process.
References:

 Manufacturing Science(Amitabh Ghosh, Asok Kumar


Mallik)
 www.wikipedia.org
 www.nptel.ac.in
 www.slideshare.net
 Degarmo’s Manufacturing Science
Thank You

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