Blanking Operation Solution
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awad.2005.omarBlanking Operation Solution
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awad.2005.omarBlanking Operation Analysis -
Comprehensive Solution
Problem Statement
A part is required to be blanked from a steel sheet of 2.5 mm thickness, having a shear
strength of 280 MPa. The clearance allowance for the given steel is 0.06.
Part (a): Press Capacity Calculation
Approach
To estimate the press capacity required for the blanking operation, we need to: 1.
Calculate the perimeter of the part 2. Determine the shear force using the formula: Force
= Perimeter × Thickness × Shear Strength 3. Apply a safety factor to determine the final
press capacity
Calculations
• Part dimensions: 50 mm width × 85 mm height with a notch (25 mm × 25 mm)
• Material thickness: 2.5 mm
• Shear strength: 280 MPa (280 N/mm²)
Perimeter Calculation
The perimeter consists of the outer edges and the notch: - Perimeter = 2 × height +
width + (width - notch_width) + 3 × notch_height - Perimeter = 2 × 85 + 50 + (50 - 25) + 3
× 25 - Perimeter = 170 + 50 + 25 + 75 - Perimeter = 320 mm
Shear Force Calculation
• Force = Perimeter × Thickness × Shear Strength
• Force = 320 mm × 2.5 mm × 280 N/mm²
• Force = 224,000 N = 224 kN
Press Capacity with Safety Factor
Applying a safety factor of 1.3 (standard for blanking operations): - Press capacity = Force
× Safety factor - Press capacity = 224 kN × 1.3 - Press capacity = 291.2 kN ≈ 29.68
metric tons
Result for Part (a)
The estimated press capacity required to perform this blanking operation is 291.2 kN
(29.68 metric tons).
Part (b): Punch and Die Dimensions
Approach
To determine the punch and die dimensions for blanking: 1. Calculate the clearance per
side using the clearance allowance 2. Determine punch dimensions (smaller than the
blank) 3. Determine die dimensions (larger than the blank)
Calculations
• Clearance allowance: 0.06
• Clearance per side = Thickness × Clearance allowance
• Clearance per side = 2.5 mm × 0.06 = 0.15 mm
Punch Dimensions (smaller than the blank)
• Punch width = Blank width - 2 × Clearance per side = 50 - 2 × 0.15 = 49.7 mm
• Punch height = Blank height - 2 × Clearance per side = 85 - 2 × 0.15 = 84.7 mm
• Punch notch width = Blank notch width + 2 × Clearance per side = 25 + 2 × 0.15 =
25.3 mm
• Punch notch height = Blank notch height - 2 × Clearance per side = 25 - 2 × 0.15 =
24.7 mm
Die Dimensions (larger than the blank)
• Die width = Blank width + 2 × Clearance per side = 50 + 2 × 0.15 = 50.3 mm
• Die height = Blank height + 2 × Clearance per side = 85 + 2 × 0.15 = 85.3 mm
• Die notch width = Blank notch width - 2 × Clearance per side = 25 - 2 × 0.15 = 24.7
mm
• Die notch height = Blank notch height + 2 × Clearance per side = 25 + 2 × 0.15 =
25.3 mm
Result for Part (b)
The required punch and die dimensions for blanking are:
Punch Dimensions: - Width: 49.7 mm - Height: 84.7 mm - Notch width: 25.3 mm - Notch
height: 24.7 mm
Die Dimensions: - Width: 50.3 mm - Height: 85.3 mm - Notch width: 24.7 mm - Notch
height: 25.3 mm
Part (c): Die Arrangement Efficiency Analysis
Approach
To determine the most efficient die arrangement: 1. Calculate material utilization for
vertical arrangement 2. Calculate material utilization for horizontal arrangement 3.
Compare the results and justify the answer numerically
Assumptions
• Standard sheet size: 1000 mm × 1000 mm
• Scrap allowance between blank and sheet edge: 5 mm
• Scrap allowance between two blanks: 5 mm
• One product per press stroke
Calculations
Vertical Arrangement (as in the figure)
• Vertical sheet width per column = Blank width + 2 × Scrap allowance = 50 + 2 × 5 =
60 mm
• Vertical sheet height per blank = Blank height + Scrap allowance = 85 + 5 = 90 mm
• Number of columns = (Sheet width - Scrap allowance) ÷ Vertical sheet width =
(1000 - 5) ÷ 60 = 16.58 ≈ 16 columns
• Number of rows = (Sheet height - Scrap allowance) ÷ Vertical sheet height per
blank = (1000 - 5) ÷ 90 = 11.05 ≈ 11 rows
• Total blanks = 16 columns × 11 rows = 176 blanks
Horizontal Arrangement
• Horizontal sheet width per blank = Blank width + Scrap allowance = 50 + 5 = 55 mm
• Horizontal sheet height per row = Blank height + 2 × Scrap allowance = 85 + 2 × 5
= 95 mm
• Number of columns = (Sheet width - Scrap allowance) ÷ Horizontal sheet width
per blank = (1000 - 5) ÷ 55 = 18.09 ≈ 18 columns
• Number of rows = (Sheet height - Scrap allowance) ÷ Horizontal sheet height per
row = (1000 - 5) ÷ 95 = 10.47 ≈ 10 rows
• Total blanks = 18 columns × 10 rows = 180 blanks
Material Utilization
• Area of one blank = Blank width × Blank height - Notch width × Notch height = 50
× 85 - 25 × 25 = 4250 - 625 = 3625 mm²
• Total area utilized in vertical arrangement = 176 blanks × 3625 mm² = 638,000 mm²
• Total area utilized in horizontal arrangement = 180 blanks × 3625 mm² = 652,500
mm²
• Sheet area = 1000 mm × 1000 mm = 1,000,000 mm²
• Material utilization in vertical arrangement = (638,000 ÷ 1,000,000) × 100% =
63.80%
• Material utilization in horizontal arrangement = (652,500 ÷ 1,000,000) × 100% =
65.25%
Result for Part (c)
The horizontal arrangement is more efficient for blanking with a material utilization of
65.25% compared to 63.80% for the vertical arrangement. This represents an
improvement of 1.45% in material utilization.
Numerical Justification: 1. Horizontal arrangement yields 180 blanks per standard
sheet compared to 176 blanks for vertical arrangement 2. This results in 4 additional
parts per sheet, improving material utilization by 1.45% 3. The horizontal arrangement is
more efficient because the part's width (50 mm) is less than its height (85 mm), allowing
more parts to be placed along the width of the sheet
Conclusion
1. The press capacity required for the blanking operation is 291.2 kN (29.68 metric
tons)
2. The punch should be 49.7 mm × 84.7 mm with a 25.3 mm × 24.7 mm notch
3. The die should be 50.3 mm × 85.3 mm with a 24.7 mm × 25.3 mm notch
4. The horizontal arrangement is more efficient for blanking with a material
utilization of 65.25%
