FINE

BLANKING
What is the definition of Fine
Blanking?
A type of blanking operation that
simultaneously compresses and shears
sheet metal in order to reduce the
amount of tearing along the edge.

Fine blanking produces blanks with

edges that are entirely smooth.
Blanking to Fine Blanking
 Conventional Blanking
Conventional blanking or stamping work produces
parts with sheared surfaces which are only
generally one third-cleanly sheared, the
remaining two thirds showing a rough break.
When functional demands are made on these
sheared or brake surfaces concerning tolerances
or quality of surface finish, then the piece parts
must be re-worked by such methods as Shaving,
Milling, Reaming, Broaching or Grinding.
 Conventional Blanking

For the production of precision devises it is

often necessary that at least two, but
generally more secondary operations are
required per piece-part.
 But in Fine-Blanking

• Precisely finished components.

• Cleanly sheared over the whole material
thickness.
• One single operation.
• Production cost savings can be made.
• In order to achieve such quality, a triple
action press and specially constructed
tools are required.
 But in Fine-Blanking

Till now max. sheet thick that can be processed in

Fine blank is up to 14mm and min. of 0.7

So, Fine Blanking is a unique metal forming process

founded on the technology of metal stamping.
Special Fine Blanking presses and custom tooling
produce parts that are too complex to make
accurately by conventional stamping.
Sheared surfaces of components produced by
Fine Blanking & Conventional Blanking
Conventional

Fine Blanked
 Features of Fine Blanking
• With Fine blanking, components of very high
accuracy are attainable tolerances of ±0.015mm are
achievable.
• Holes with a diameter as small as 60% of the
material thick can be pierced.
• Material up to 14mm thick can be Fine blanked.
• The edge quality and accuracy of the fine blank
process can eliminate the need for secondary
processes e.g. reaming of holes or shaving to get a
square smooth edge.
• Components remain very flat.
 Features of Fine Blanking
• Components can have features such as
Countersinks, Extrusions, Semi-pierces, Weld
projections, Coined chamfers, Counter bores,
and offsets applied to them in the pressing
operation.
• Tooling is generally of a compound nature.
This ensures superior positional accuracy
between features.
• Tooling prices are competitive compared
with conventional tooling.
• Virtually any metal can be Fine blanked
SAMPLE COMPONENTS
Where are fine-blanked parts required?
• Office machines.
• Household appliances
• Communication equipments.
• Watch and Clock industry.
• Cinema and photographic appliances.
• Sound reproduction.
• Automobile industries.
• Electrical industry.
• Measuring and regulation equipment.
• Aircraft industry.
• General machines and Equipment
application.
• Surgical equipments.
APPLICATIONS OF FINE BLANKING
APPLICATIONS OF FINE BLANKING
 Fine blanking Economies
Fine blanking is a process that provides parts with
smooth edges and high accuracy. Because of the
stability and precision of the process many
secondary operations can be eliminated. These
include:
• Grinding
• Milling
• Broaching
• Reaming
• Gear Hobbing
• Forming
• Shaving
• Leveling
 Fine Blanking Economies

• Fine blanking can produce, in a single step, a

part that would require multiple operations,
set-ups, and man hours using other
processes.

• Fine blanking becomes more economic, the

more chip making operations can be
eliminated and the larger the production
batch is.
 Fine Blanking Economies

• The production capacity and the reliability of

the Fine Blanking line are also extremely
important.

As a result Fine blanking is frequently the

lowest total cost option.
 The Economy of Fine Blanking
Fine blanking is an economic production method
because of the following advantages:
• Automatic manufacturing
• Elimination of secondary operations
• High production
• Continuous good quality
• Reduced space requirement for the
production line
• Less material handling
 Working Principle

Fine Blanking tool is a special tool

incorporating the smaller clearance (0.01mm or
even lesser). The Vee ring around the counter is
pressed on to the sheet giving a relatively greater
press force on the cutting line.
 Working Principle

OPERATIONS:

A. Strip is fed
B. Locating and pressing with V-ring.
C. Blanking and tensioning the ejector
D. Strip is lifted by the punch.
E. Component ejected.
F. Stripping
G. Component removed from the tool.
Fundamental principles of the fine blanking.
THE FINEBLANKING TECHNOLOGY is a process
of the press working technique which makes it possible
to produce, in one single operation, precise finished
components cleanly sheared over the whole material
thickness, with close dimensional tolerances and being
free from fractures and cracks in their functional areas.
Fundamental principles of the fine blanking.
Not only flat parts are produced but also work pieces
incorporating numerous forming operations, such as
Bends
Off-sets
Coining
Extrusions
are also manufactured, fine blanking provides the
capability pierce holes of smaller diameter than
material thickness.
 V-Rings

Before the actual cutting begins the material

is firmly sandwiched between the die and
V-Ring plate. This prevents the material from
flowing laterally. The material is also held by
a so called V-Ring that is formed into the
material along the outside contours of the
part.
 V-Rings
The die as well as the V-Ring plate are
subject to wear and can be re-worked
several times. Therefore, the V-Ring is
machined into the hardened steel.
Two methods are used to make the V-Ring
(stinger):
a) By EDM (Electrical Discharge
Machining)
b) Milling with tungsten carbide cutter
I. Milling of the inside
II. Milling of the outside
III. Milling or grinding of the
remaining
surface
 Strip width and the margins

Because of the presence of the V ring the margins and

hence the strip width must be slightly larger than in
conventional blanking.

Scrap bridge (stock thickness) =1.5 to 2mm x S

S = Material thickness.

For thinner material higher value,

For thicker material lower the value.
Strip width and the margins
 Strip layout considerations for Fine Blanking

On sections of the part with no functional requirements on

fine- blanked surface, the ‘vee-ring’ indenter can be
eliminated.

For tooth profiled components the tooth profile

should be always opposite to the strip feed direction.
THE PRESS FORECE

The Press force is a combination of the three

forces. They are Cutting force (FS ), Vee ring force
( FR) and Counter force (FG)
 The most important factor for determining
the type of machine to be used is the cutting
force. In practice the formula used is as
follows:

FS = L x S x T max
FS = Blanking or shearing force (tones)
L = Total of outer and inner shear periphery
lengths (mm)
S = Material thickness (mm)
T max = Shear strength (N/mm²)
The exact shear pressure is influenced by
the following factors:
• Condition of the edges of the cutting elements
(punch and die plate).
• Punch-Die clearance.
• Shear speed.
• Geometric form of the part.
• Metallurgical structure of the material.
• Type and amount of cutting lubricant.
• Surface finish of the cutting elements.
• Tolerance of the material being worked.
Relation between Shear force,
Vee ring force & Counter force:
If Shear force FS = ‘x’ tones then,
Vee ring pressure FR = 40% to 60% of ‘x’ (shear force)
Counter pressure FG = 50% of Vee ring pressure

Total Press force F = FS + FR +FG Tones

PUNCH AND DIE CLEARANCE

Ideally the distance between the punch and the die at

any given position is ½ of the punch-die clearance.

The Punch-Die clearance is normally calculated at

1% of the material thickness to be worked.

For Gear-wheels the clearance in the areas of the

tooth crests and tooth root are doubled(2%). This
also applies to forms which re-enter into the piece-
part.
MINIMUM DISTANCE FROM THE DIE APERATURE

From the die aperture extreme to the die plate

parameter:

For Ground / Split dies = 25 mm

For Solid / Eroded dies = 35 mm
MINIMUM DISTANCE FROM THE DIE APERATURE
TOOL LIFE

The number of components that can be produced out

of the tool between the consecutive grinding depends
on
a. Strip material
b. Sheet thickness
c. The characteristics of the press
d. The quality of the Fine blanking tool
TOOL LIFE

The possibility of the punch failure in the Fine

blanking tool is about three times more as compared
to the die failure. Hence the corners and round
portions are rounded.

For materials like Aluminium, Copper etc. about

1,00,000 components can be produced between the
grindings. For steel the quantity is about 31,000.
SHEET THICKNESS

The thickness of the material has limitations because of

the presence of the V-ring. Hence the thickness of less
than 0.7mm is difficult to manage, between 0.7 to 4mm
thickness, the Fine blanking operation can be carried out
without any problem.

With the present experience a material thickness up to

14mm can be handled.
PUNCH AND DIE RADIUS

Before the tool is mounted on the press for trial, Round

off the die aperture and piercing punches lightly. It
improves the condition for better flow of the material.

Start the trial with minimum radius of the cutting edges of

the die and piercing punches and slowly increase till a
clean cut edge is available on the component.
Rounding the Cutting edges.

Punch

Die

Radius
FINE BLANKING MATERIALS

The materials used for pressing can originate from one of

the following groups:

a. Aluminum and its alloys

b. Copper and its alloys
c. Steel, alloyed steels
d. Standard steels
FINE BLANKING MATERIALS
INFLUENCE OF MATERIAL
The property of the Fine blanking material can be described by
the following parameters:
a. Tensile strength
b. Elastic limit
c. Elongation
d. Hardness
e. Degree of cementite and carbide desperation

The best suitable fine blanking material with a high form

changing capability must present the following
properties:

Tensile strength N/mm² Low

Elastic limit N/mm² Low
Elongation % High
Reduction of area % High
FINE BLANKING MATERIALS
Materials suitable for Fine blanking.

Working materials that can be fine blanked with good

results include low and medium carbon steel, some alloy
steels, some Stainless steels, in the soft (annealed)
condition where hardness/strength is low and ductility is
high and Copper, Brass, German silver and Aluminum
also can be blanked.
LUBRICANTS

Fine blanking is impossible to perform without lubrication.

The process would lead to cold welding of the active

elements to the blank

Lubricant forms a film in the between the cutting tool

edges and material thereby reducing the wear.
WORK HARDENING DURING FINE BLANKING

Due to the fact that in the shear zone area the crystals of
the material structure are made to flow, an increase in
the hardness of the Fine blanked parts results( in the
sheared surface and in other zone).

Fine blanked parts will have to fulfill a function, where

there is a wear on the sheared surface have advantages
of approximately 100% greater hardness on the sheared
surface than the initial material hardness.

Due to the cold forming of the crystals in increase in

hardness can be practically exploited.
Types of Fine Blanking tool.
• Tool with Sliding (moving) punch.
• Tool with Fixed punch.
MOVING PUNCH SYSTEM.
 TOOL WITH SLIDING (MOVING) PUNCH

1. Blanking punch 10. Piercing punch

2. Die plate retaining plate
3. Ejector 11. Pressure pad
4. Guide Vee-ring plate 12. Punch base
5. Inner form punch 13. Ejector bridge
6. Inner form ejector pin 14. Back plate
7. Pressure pins 15. Latch bolt
8. Back-up plate 16. Upper frame
9. Holding ring 17. Lower frame
18. Guide unit
TOOL WITH SLIDING (MOVING) PUNCH

Most decisive factors are:

• Sliding punch designs are the simplest Fine
Blanking tools as far as design, construction
and maintenance are concerned.
• Accuracy of the tool.
• Position accuracy between inner and outer forms,
• Burr of inner and outer form on the same side.
• Cutting elements of tool have to be cylindrical, so
that part of identical dimensions can be produced
during the whole tool-life.

Preferably used for:

Parts up to thickness S = 4mm.
Parts with few inner forms.
FIXED PUNCH SYSTEM
 TOOL WITH FIXED PUNCH
1. Blanking punch 11. Intermediate plate
2. Die plate 12. Back-up plate
3. Ejector 13. Pressure pins
4. Inner form punch 14. Latch bolt
5. Piercing punch 15. Guide plate
6. Inner form ejector 16. Upper frame
7. Ejector pins 17. Lower frame
8. Vee-ring plate 18. Guide unit
9. Pressure plate 19. Shrink ring
10. Piercing punch retaining
plate
TOOL WITH FIXED PUNCH
Most decisive factors are:
• Accuracy of the tool.
• Position accuracy between inner and outer forms,
• Burr of inner and outer form on the same side.
• Cutting elements of tool have to be cylindrical, so
that part of identical dimensions can be produced
during the whole tool-life.

Preferably used for:

• Parts of any size and thickness.
• Parts with any numbers of inner forms.
TOOL WITH FIXED PUNCH
 Materials used for tool manufacturing.

Die plate D6,D2

Large inner form punches D2
Piercing punches &
Small inner forms. M2
Shroud ring. O1,O7
Retainer plates,
Pressure plates,
Backup plates. O1,O7
Pressure pins. O1,O7
All types of bushes,
Pillar, EN31
Alignment pin. E230
THANK
YOU