Blanking, Shearing and

Trimming
October 15th, 2014

Hyunok Kim, EWI Forming Center

Taylan Altan, OSU - Center for Precision Forming (CPF)

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Process Definition - Blanking
Blanking/piercing is defined as cutting parts out of sheet
material to a predetermined contour that is defined by the
punch and the die.
rollover
punch motion
shear zone

secondary shear
punch
blank
hold er rupture zone

w orkpiece burr

depth of the crack

d ie
penetration

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Phases of the Blanking Process

Rotor and stator blank of an Courtesy: Schuler Inc.

electric motor

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Process Definition - Shearing
The material is separated
by two shears which are
in close proximity to
each other and which are
moving in opposite
directions. The cutting
line does not have a
closed contour.

Courtesy: Schuler Inc.

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Process Definition - Trimming
Trimming is an operation in which scrap is cut away from a
workpiece along a predetermined cutting line (opened or
closed) to correctly shape the entire or part of a workpiece.

(Kalpakjian, 1997)

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Parameters affecting the part
edge quality
For most applications it is desired to achieve a straight part edge
with negligible rollover, rapture zones and burr. However, it may be
advantageous to have a large depth of the crack penetration for
easier part assembly.
Parameters affecting the part quality:
Punch-die clearance
Cutting velocity
Material thickness
Material properties
Cutting tools
Lubrication
Part geometry

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Effect of punch-die clearance
on part edge quality
Punch die clearance has the largest influence on the
formation of the part edge. Decreasing the punch-die
clearance has usually the following effects:
Less rollover
Small burr
More shear and less rupture
Therefore, decreasing punch die clearance results in
better part edge quality. However, small clearances
(< 8% of the material thickness) result in high
stresses and strains on punch and die.

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Process to improve part edge
quality Fine Blanking

Courtesy: Schuler Inc.

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Comparison of blanking with
fine blanking

Work result for standard blanking (left) and fine blanking (right)
Courtesy: Schuler Inc.
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Example Fine Blanked Part

Indexing cam: fine blanked part with differing degrees of difficulty

Courtesy: Schuler Inc.

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Force-Time Curve for Blanking

Force-time curve for blanking of sheet metal

Courtesy: Schuler Inc.
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Load-Stroke Curve for Blanking

[Breitling,1997]
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Blanking Force
Blanking force can be calculated based on the shear resistance of
the material and the dimensions of punch, die and sheet.

F d t s [Aida, 1994]

Where ,
d: disk diameter;
t: sheet thickness;
s: shear resistance of the material .

This equation may be also used for non-round punch by calculating the
shear area based on the actual length of the punch contour and the
material thickness.

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Blanking Force Reduction with
Inclined Punch Shape

Blanking force reduction with inclined punch shape

Courtesy: Schuler Inc.

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Blanking Force Reduction Using
Special Tool Shape

Punch and female die shapes (h = difference in height)

Courtesy: Schuler Inc.

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FEM in Blanking Process
When the damage value is reached at a certain element, the
element is deleted. DEFORM 2D includes a fracture feature which
is capable of simulation all the phases of a shearing operation.

Simulated part edge Experimental cross section of a blank (a) and a skeleton (b)
15% clearance, sharp tool and low carbon steel [Breitling,1997]

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Blanking a conventional chain
wheel for a motor cycle

Conventional chain wheel production for a motor cycle (top row):

1. Blanking the outside contour; 2. Piercing the inside hole; 3.piercing four windows; 4. Leveling;
5.turning the inside wheel and chamfering on both sides; 6. Milling the teeth in the stack; 7.
Bevel turning of tooth tips on both sides; 8. Boring holes and deburring; 9. Grinding
Production using fine blanking (bottom row):
1. Fine blanking; 2. Bevel turning of tooth tips on one side, 3. Deburring
Courtesy: Schuler Inc.

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Summary
Piercing / Blanking is a very important operation because
the edge quality of the pierced hole or blanked sheet
affects the quality of subsequent flanging and edge
cracking
The edge quality in Piercing/Blanking is affected by:
a) Punch / die clearance
b) Cutting velocity
c) Blank material properties and thickness
d) Punch/die geometry
e) Blank holder pressure
It is desirable to select the best above listed parameters
for a given blank (material and thickness)

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Questions & Contacts
Taylan Altan Hyunok Kim
614.292.5063 614.688.5239
altan.1@osu.edu hkim@ewi.org