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Fineblanking Economies
Fineblanking 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
Fineblanking can produce, in a single step, a part that would require multiple operations, set-ups, and man-hours
using other processes. As a result Fineblanking is frequently the lowest total cost option.
• fineblanking press
• fineblanking tool
• malleable material
Sequences of Fineblanking
Forces
A strip lay-out is made to determine the strip width and pitch. The bridge width between the parts and the edge
allowance between the part and the edge of the strip have to be selected to meet the following requirements:
Complex contours or sections that require smooth edges, should be located on the in-feed side of the strip (arrow)
because the solid strip is more rigid than the bridge between the parts.
An edge allowance that is smaller than indicated in the table below can be selected if the edge allows die break or if the
section that runs parallel to the edge of the strip is shorter than 5 x stock thickness (L < 5s).
The optimum pitch, i.e. the smallest possible bridge width can be determined in tests. Very often the V-Rings can
overlap without a negative effect on the surface quality of the sheared edge.
Fineblanking Accuracy
The accuracy that can be achieved in fineblanked parts is largely dependent on:
Caution: The following table should be used as the engineering limit of the Fineblanking process. It
assumes perfect tooling, excellent cold rolled mild steel material, and a non-complex part geometry.
In the real world, these values need to be adjusted for high carbon steels, stainless steels, and complex part
geometries. A good place to start is two times these values, and you will be very safe at three times these
values.
The following tables use the ISO 286 system of tolerancing. If
this is unfamiliar to you, there is an excellent treatment at
www.roymech.co.uk ( under shaft tolerances). If you do any
work with fits (slip fit, force fit, etc.) this system will save you a
ton of work. But it is not necessary to understand the system to
use the tables, but that is where IT7, IT8, etc. come from. Now
on to the tables.
Fineblanking Tolerances
Tolerance .040 to .150 to .300 to .400 to .700 to 1.20 to 2.00 to 3.00 to 4.75 to 7.00 to
Class .150 .300 .400 .700 1.20 2.00 3.00 4.75 7.00 10.00
IT 7 0.0004 0.0005 0.0006 0.0007 0.0008 0.001 0.0012 0.0014 0.0016 0.0018
IT 8 0.0005 0.0007 0.0009 0.001 0.0013 0.0015 0.0018 0.002 0.0025 0.0028
IT 9 0.001 0.0012 0.0014 0.0017 0.002 0.0024 0.0029 0.0034 0.0039 0.0045
IT 10 0.0015 0.002 0.0023 0.0028 0.0033 0.0039 0.0047 0.0055 0.0063 0.0073
In mild steel grades such as 1008/ 1010 Cold Rolled, surface finishes of 16 microinches are obtainable. As the
material gets harder, and therefore less ductile, edge condition will suffer. Use of full sheroidized annealed
material is necessary in many applications.
Fine blanked edges are also extremely perpendicular to the face of the part. For a .25 thick part, perpendicularity
of .001 inches is obtainable.
The table below shows how edge finish is related to the die sharpening schedule.
s = Material thickness
h 1 = Smooth land in % of s (to the begin of die break)
h 2 = Smooth land in % of s (to peak of die break)
b = Width of peak. The max. width b must not be larger
than the material thickness s. The sum of all b's
must not be more than 10 % of the marked circumference.
t = Die break approx. 1,5 % of s.
E = Determines, that tear is permissible along the marked
circumference.
The following diagrams show the recommended design radii. They are divided into three ranges, depending on
part difficulty:
For range C), the tensile strength of the material should not exceed 600 N/mm2 (40 tsi).
For values outside the range C), the tool life drops considerably.
Limits of the Geometrical Shape - Slots and Holes
One of the great advantages of Fine blanking is its ability to produce very fine features. Slots or holes can be
placed very near to the edges of the part, or near each other.
Also, fineblanking can produce holes that are much smaller (as compared to material thickness) than can be
produced by conventional stamping.
The Tables below show the recommended design guidelines for slots and holes.
1) Accurate
2) Perpendicular
3) Smooth
Fine blanking is the only metal stamping process that can produce a gear in a single operation.
The table below shows the design limits for gear teeth.
The different kinds of steel used for fineblanking can be divided in four groups:
Group 1
Low carbon steels are the most suitable for fineblanking and are usually processed without any special heat
treatment.
treatment.
Group 2
Unalloyed steels can be fineblanked with a carbon content of up to 1 % with a spheroidal cementite structure
(90 - 100 %). If the carbon content exceeds 0.1 %, a heat treatment is necessary to achieve clean sheared
edges.
Groups 3 + 4
Alloyed steels also need a structure with well formed carbides. To avoid tears, the geometrical shape of the
part should not be too complex.
For fineblanking cold or hot rolled steels are used. If necessary, cold rolled stock can be rolled to a higher
strength after annealing. The scale on hot rolled material has to be removed by pickling.
Structure of steel with a carbon content of o, 75% in different spheroidal grades (V=35o : 1).
20% 50%
Tensile Strength
The tensile strength of unalloyed
steels depends extensively on the C -
content and structure.
If a part requires a high surface strength, it is advisable to fineblanking a low in carbon steel and to bring the
part afterwards to the required strength by casehardening.
The material influences extensively the quality of sheared edges and the tool life of the cutting elements.
Fineblanking becomes more difficult:
Fineblanking Tools
Tool systems
Sliding punch tools are easier to design and manufacture so they are cheaper than fixed
punch tools. But for some applications, sliding punch design can weaken the tooling
elements and shorten die life. Costs for sliding punch tools are in the range of $5000 to
$15,000.
Fixed punch tooling has a more robust tool design which makes it the choice for heavy
blanking pressures and long runs. However, the cost is prohibitive for short to medium run
tools. Costs for fixed punch tools are in the range of $10,000 to $30,000.
As you can see, fine blank tooling is more expensive that conventional stamping tools.
This is due to the need for expensive tool steels and extreme accuracy in manufacture.
Partech has developed a low cost tooling system for small parts, so if your applications
will fit inside a 9 inch circle, please contact us for a competitive quote.
Fixed Punch Tools
Lateral forces occur during fineblanking. It therefore makes sense to absorb these lateral forces in large size die
sets with plain or roller bearing bushings. The initially higher costs are easily compensated for by the longer tool
life.
The blanking force is directly transferred to the die plate by the bottom die shoe.
The V-ring force (stripper force) is transferred to the V-ring plate (stripper) by pressure pins. The counter force
(ejection force) is also transferred by pressure pins to the counter punch (ejector).
Tool Standards
The most economical manufacturing of fineblanking tools can be done if the die sets and their
components are manufactured in series.
components are manufactured in series.
Therefore, SCHMID has designed a standard line of die sets, which is available from stock. A full set
of detailed drawings is provided with each press.
For each type of press, SCHMID has different sizes of standard die sets. The choice depends on the
size of the fineblanking component.
Unlike conventional metal stamping dies, Fine blank tooling must withstand heavy tensile
stress as well as the normal compressive stress. This forces the die builder to use the
best tool steel material available. Depending on the die element CPM 10V, M4, M2, or D2
tool steels are utilized.
Tool manufacturing
As shown above, a completed fineblanking tool is very robust. Note the four-bushing die
set needed to maintain tool alignment.
Also note the air blast lines shown on the lower left. These lines eject the parts and slugs
from the tool, where they are then separated by a vibrating screen.
Methods of Tool Construction
-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.
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.
Experience has shown that milling the V-Ring is not only very
economic but also provides a better quality, as no changes occur
in the metallurgical structure.
I. milling of the inside
Fineblanking Machinery
Production line
The fineblanking press is the heart of an automatic fineblanking production line, which usually consists of the following
components:
Fineblanking Presses
There are two kinds of fineblanking presses:
Mechanical fineblanking presses are mainly used to manufacture relatively thin and small parts. Components
with a thickness of more than 3 mm, requiring a total force of 100 tons and more, are in the majority
produced with fully hydraulic fineblanking presses.
Shmid Presses
SCHMID manufactures fully hydraulic fineblanking presses with the following total forces in metric tons: 100,
160, 200, 250, 320, 400, 630, 800 + 1000 tons.
The design and manufacturing of the presses and accessories are completely done in our own facilities. The
design of all presses follows a common concept, which allows the extensive use of modular and standard
components. This advantage results in comparatively low investment and maintenance costs.
Examples of Applications 1
Fineblanking parts are used in machines and equipments produced in large quantities where the
functioning of the components arks for high accuracy.
The following example show some of the most important fields of application.
Examples of Applications 2
In these applications, Fine blanking is used to produce both internal and external gear forms. This eliminates
the need for secondary gear hobbing or grinding.
Exampl
es of
Applica
tions 3
In these
examples please
note how
versatile the Fine
blanking process
can be. Small,
delicate
electronic
components can
be produced
using the same
equipment that
produces large
industrial
components.
Examples of Applications 4
Shown below are some good examples of Fine blanked components. They show the fine detail and flatness
that can be achieved by the Fine blanking process.
The Economy of Fineblanking
Fineblanking 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
Fineblanking becomes more economic, the more chip making operations can be eliminated and the
larger the production batch is. The production capacity and the reliability of the fineblanking line are
also extremely important.
IT Grade 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Lapping X X X X
Honing X X X
Superfinishing X X X
Cylindrical Grinding X X X X
Diamond Turning X X X X
Plan Grinding X X X X X
Broaching X X X X X
Reaming X X X X X
Fineblanking X X X X
Boring, Turning X X X X X X
Sawing X X X
Milling X X X X X
Planing, Shaping X X X X X
Extruding X X X X
Drilling X X X X
Die Casting X X X X
Forging X X X X
Sand Casting X X X