Chapter 8

FINE BLANKING

FINE-EDGE BLANKING AND PIERCING

Fine-edge Blanking (also known as fine blanking, smoothedge blanking, or fine-flow blanking) produces precise blanks in a
single operation without the fractured edges characteristically
produced in conventional blanking and piercing. In fine-edge
blanking, a V-shape impingement ring (see fig. In next slide) is
forced into the stock to lock it tightly against the die and to force
the work metal to flow toward the punch, so that the part can be
extruded out of the strip without fracture or die break. Die
clearance is extremely small, and punch speed much slower than
in conventional blanking.

FINE-EDGE BLANKING AND PIERCINGE

No further finishing

Typical tooling setup for the fineedge blanking a simple shape

or machining operations
are necessary to obtain
blank or hole edges
comparable to machined
edges, or to those that are
conventionally blanked or
pierced and then shaved.
A quick touchup on an
abrasive belt or a short
treatment in a vibratory
finisher may be used to
remove the small burr on
the blank

FINE-EDGE BLANKING AND PIERCING

Holes can be pierced in low-carbon steel with a
diameter as small as 50% of stock thickness. In highcarbon steel, the smallest hole diameter is about 75% of
stock thickness. Holes can be spaced as close to each
other, or to the edge of the blank, as 50 to 75% of stock
thickness. Total tolerances obtainable are: 0.0125 mm. on
hole diameter and for accuracy of blank outline; 0.025
mm. on hole location with respect to a datum surface and
0.025 mm. on flatness.
PROCESS CAPABILITIES

FINE-EDGE BLANKING AND PIERCING

Metals up to 3 mm. thick having a tensile strength of
6,000 to 8,000 Kg. / sq. cm. are easily blanked. Parts up
to 12 mm. thick can be blanked if press capacity is
available. Material thicker than 3.2 mm., especially steel
having a carbon content of 0.25% or more, requires an
impingement ring on the die so that the corners on the
part will not break down. The edges of parts made of
1018 steel work harden as much as 7 to 12 points
Rockwell C during blanking.
PROCESS CAPABILITIES

FINE-EDGE BLANKING AND PIERCING

Limitations on blank size depend on stock thickness, tensile
strength and hardness of the work metal, and available press
capacity. For example, perimeters of approximately 63.5 cm. can
be blanked in 3.2 mm. thick low-carbon steel (1008 or 1010). It is
possible to blank smaller parts from low-carbon or medium-carbon
steel about 12.7 mm. thick.
Sharp corner and fillet radii should be avoided when
possible. A radius of 10 to 20% of stock thickness is preferred,
particularly on parts over 3.2 mm. thick or those made of alloy
steel. External angles should be at least 90. The radius should be
increased on sharper corners or on hard materials.
BLANK DESIGN

FINE-EDGE BLANKING AND PIERCING

A triple-action hydraulic press or a combination hydraulic
and mechanical press is used for fine-edge blanking. The action is
similar to that of a double-action press working against a die
cushion. An outer slide holds the stock firmly against the die ring
and forces a V-shape impingement ring into the metal surrounding
the outline of the part.
The stock is stripped from the punch during the upstroke of
the inner and outer slides. An inner slide carries the blanking
punch. A lower slide furnishes the counteraction to hold the blank
flat and securely against the punch. This slide also ejects the blank.
PRESSES

FINE-EDGE BLANKING AND PIERCING

The stripping and ejection actions are delayed until after the
die has opened at least to twice the stock thickness, to prevent the
blank from being forced into the strip, or slugs from being forced
into the blank. Because loads are high and clearance between
punch and die is extremely small, the clearance between the gibs
and press slides must be so close that they are separated by only an
oil film.
Force requirements for fine-edge blanking presses are
influenced not only by the work metal and the part dimensions, but
also by the special design of the dies and pressure pads used for
fine-edge blanking. Depending on part size and shape, a 100-ton
press can blank stock up to 8 mm. thick; a 250-ton press, up 12
mm. thick; and a 400-ton press, up to 13mm. thick.
PRESSES

FINE-EDGE BLANKING AND PIERCING

The total load on the press in fine-edge blanking is
the sum of three components: the cutting force (Lc); the
lower blank holder force (LLB) or counterforce and the
clamping force on the impingement ring (LLR) on the
pressure pad. The first two components comprise the
total force on the inner slide, and the third component is
the force on the outer slide.
PRESSES

FINE-EDGE BLANKING AND PIERCING

A basic tool comprises three functional components: the die,
the punch, and backpressure components. To produce good-quality
blanks, the punch-to-die clearance must be uniform along the entire
profile and must be suitable for the thickness and strength of the work
metal. The clearance varies between 0.0050 and 0.01 mm.
The components of a typical tooling setup for fine-edge
blanking of a part of simple shape are shown in fig. The pressure pad
guides the profile part of the blanking punch. A round punch is
prevented from rotating by a key fastened to the upper die shoe. The
hardened pressure pad is centered by a slightly conical seat in the
upper die shoe; this pad contains the V-shape impingement ring.
DESIGN

FINE-EDGE BLANKING AND PIERCING

Fine blanking tool with fixed punch

FINE-EDGE BLANKING AND PIERCING

Because of the high loads, close tolerances, and small
clearances involved in fine-edge blanking, the die elements are made
of high-carbon high-chromium tool steels, such as D2 or D3, or of A2
tool steel, heat treated to about Rockwell C 62.
Punch and the die life vary with tool material and hardness,
punch-to-die clearance, type of work metal, and work piece
dimensional and surface-finish tolerances.
For most work metals under the usual operating conditions,
punch life for fine-edge blanking of 13.2 mm. thick stock is 10,000 to
15,000 blanks between regrinds assuming that the blanks are of
simple shape and that punch wear is such that only 0.05 to 0.125 mm.
of metal need be removed to restore the punch to its original
condition.
Materials and Life

FINE-EDGE BLANKING AND PIERCINGE

Height of impingement
ring depends on the
thickness and ductility of
the work metal. The
height (penetration) of
the V-shape is 20% of
stock
thickness
for
materials
of
low
ductility. The
more
ductile materials require
a penetration of 32 to
35% of stock thickness.
PRESSURE-PAD IMPINGEMENT RINGS

FINE-EDGE BLANKING AND PIERCING

Stock up to 4 mm. thick usually requires a ring on
the pressure pad only. Stock up to 4.8 mm. thick may
need a partial ring on the die in addition to a full ring on
the pressure pad. Full rings on the pressure pad and the
die may be necessary for stock over 4.8 mm. thick.
Although an impingement ring on the die reduces
the edge radius on the blank more than does a similar ring
on the pressure pad, its use is avoided when possible,
because it makes re-sharpening of the die difficult.
Effect of Stock Thickness

FINE-EDGE BLANKING AND PIERCING

The work metal must have a film of oil on both
sides to lubricate the punch and die during fine-edge
blanking. The lack of a lubricant on either side can reduce
punch or die life between sharpening as much as 50%.
Oils used for conventional blanking usually are
satisfactory. In severe applications, a wax lubricant may
be used. In case studies 2, 3 and 1, sulfur-free oil was
used to lubricate the strip. Extreme-pressure chlorinated
oil was used in case study 1.
Lubrication

CASE STUDY 1
Blanking of a Long Slender Lock Lever to Close Tolerances

A lever for a pushbutton lock was fine-edge blanked to a minimum total

tolerance of 0.075 mm. The maximum total dimensional tolerance was 0.25 mm.
except on fractional dimensions, which had a tolerance of 0.8 mm. The lever was
blanked from cold rolled, commercial quality 1010 steel, 3.2 mm. thick and 70
mm. wide. The coil stock had a No. 4 temper (soft), No. 3 edge (slit), and a No.
2 finish (bright). The blank design was positioned at an angle on the strip, with a
progression of 22.2 mm. An impingement ring 1 mm. high was used on the
pressure pad.

CASE STUDY 2
The clutch dog shown in fig.
was fine-edge blanked from
annealed
cold
rolled.
Commercial quality 8617 steel,
3.2 mm. thick and 38 mm.
wide. The two holes were
pierced at the same time the
outline was blanked. The
periphery of the part and the
holes had a 100% land. There
was no edge radius on the die
side, and the burr on the punch
side was small and easy to
remove.
Fine-Edge Blanking and Piercing to Final Size and Finish,
Which could not be done by conventional blanking.

CASE STUDY 3

The positive clutch detent shown in fig. was fine-edge blanked from annealed, cold
rolled, commercial quality 8617 steel, 3.2258 / 3.1242 mm. thick. The two holes
were pierced and the blank was severed from the stock in one press stroke. There
was no distortion where the edge distance was less than work-metal thickness.
Positive detent that was produced by fine blanking and piercing.

CASE STUDY 4
The blanking die was made of D2
tool steel, hardened to Rockwell C 60
to 61, and ground to a finish of 0.63
micro-mm. Impingement rings, 0.889
to 1.016 mm. high and 81.7372 mm.
in diameter, were used on both the
pressure pad and the die. The feed
length (strip progression per stroke)
was 83.312 mm. The die was set up
in a special 110-ton hydraulic press
with three slides. The press operated
at 10 to 15 strokes per minute. Die
life was 12,000 pieces per grind.
Lubricant was sulfur-free oil, applied
to both sides of the stock.
A 48 teeth spur gear that was made in one press stroke by fine edge blanking

CASE STUDY 5

The latch part shown in fig. was made of 3.2 mm thick low-carbon steel having a
No. 1 temper and a No. 2 finish.
latch part that was produced more economically by fine-edge blanking
and piercing than by conventional blanking and machining.