Blanking Die Parts

Top Plate Punch

Punch Retainer Plate

Stripper Plate Guide Post

Gage

Lifter Plate

Spacer Ring

Guide
Post
Support
Block

Spacer Blocks Die Block Die Support Block Bottom Plate

 Lower half of Blanking Tool
The Lower half of a Blanking Tool is clamped on the Bolster of the press.

The following are the parts of the Lower half of a Blanking Tool:

1. Die Block
2. Die Support Plate
3. Spacer blocks
4. Gages
5. Stopper
6. Bottom Plate
7. Scrap Chute
8. Lifting hooks
9. Guide post / Guide Bush set
 Die Block
Die Block is the female member of the Blanking Tool. The Die Block along with the
Blanking punch performs the function of Blanking. There is cutting clearance
between Die block and Punch. The Die Block is a rectangular block. It is made
up of hardened tool steel (HCHCr, D3)

The following are the considerations in designing a Die Block:

1. Cutting Force = Cutting length x Sheet thickness x shear strength

2. Minimum Die Block thickness = (Cube root of cutting force in kgs) mm
3. Die Block opening size = Blank size e.g. For cutting a blank of 60 x 100 the Die
Block opening will have the size of 60 x 100. The Blanking punch will be
smaller than the aforementioned size.
4. Minimum distance between Die block opening and Die Block edge = Die
thickness.
5. Minimum distance between bolt / dowel hole and Die opening edge will be D
if D is the size of the hole. This is to avoid cracks in the Die block during heat
treatment.
6. Minimum distance between hole edge and Die outer edge = Dia of hole.
7. Upper portion of Die opening is called land. This is where the punch enters the
Die Block. This straight portion is called Land.
8. The lower portion of die opening is relieved at angle for easy falling of blank.
 Dia D
1D – 2D

1D – 2D A Dia Opening Size =

Dia d
Die Block Blank Size

Min = d A

A
A
Minimum A = Die Thickness
Cutting Die Cross Section
Straight portion (Land)

Angular Clearance 2 Degrees

 Split Die Block
Many a times the Die Block is made up of several Die Inserts instead of being made from one
block. The reasons for splitting are as follows:

1. Usage of a single Steel Block can result in increased distortions during heat treatment
resulting in weakening of the Die Block.
2. Bigger parts need bigger steel blocks which are extremely difficult to be made out of a
single die block e.g. Bonnet, Door and other automobile panels. The difficulty in
manufacturing are mostly related to heat treatment constraints.

3. In case of any breakage, it is much easier to replace an insert instead of replacing full die
block.

The following are the considerations in designing a split die:

1. Die insert length should not exceed 200 mm to minimize distortions during heat
treatment.
2. The parting line between adjoining inserts should not lie on a corner radius.
3. The parting should not form a knife edge or sharp edge. Included angle between the
parting sides should not be less than 70 degrees.
4. The inserts should be housed inside a housing plate to avoid side thrust in inserts.
5. The height of the housing should be equal to the height of the inserts. Minimum height
of the housing = Height of the inserts minus 5 mm.
6. Each Insert should be bolted and dowelled individually to the Lower plate.
 Die Splitting
after radius
Die Splitting at
radius. Not a
Die Block Inserts end. A better
design
good design

Maximum 200 mm
Sharp edge.
Not a good
design

A Sharp
A edge
avoided.
Die splitting Good
after the design
radius ends
 Die Housing

Min Die
Housing Block.
Height = Die
Inserts height
minus 5
 Punch
Punch is the male counterpart of a Die Block. Punch and Die together are used in cutting a
sheet metal stock. A blanking punch is straight in profile. Punch is a part of the upper
tool. It is either bolted to the Top plate as in case of bigger punches or it is held in
position by Punch plate. In case a punch plate is used then a collar at the top end helps
in retaining it inside the punch plate. There is location fit between the punch and punch
plate.

The design considerations for blanking punch are as follows:

1. There is a gap between the blanking punch and die. The gap is equal to the cutting
clearance all around e.g. When blanking die opening is 60 mm dia and cutting clearance
is 0.1 mm per side, the punch dia = 59.8 mm
2. Punch is held in position by punch plate (for small punches). Refer punch ‘a’ and ‘c’ in the
next figure
3. Punch may be directly bolted and dowelled to the top plate (for large punches)
4. Sometimes the punch may be positioned by punch plate and be bolted at the top end to
the back plate. Refer punch ‘b’ in the next figure.
5. The punch is made of hardened high carbon high chromium steel (HCHCr) e.g. SKD11,
En31. D2. D3, D4.
6. Punch hardness is 55-60 HRc.
7. Rectangular straight punches are made out of rectangular blocks by milling, surface
grinding, hole drilling, hardening, tempering and wire cut EDM.
8. Cutting force can be reduced by giving taper on the bottom side of the blanking punch as
shown in figure on next page.
9. Collar type punches considerations are given on next pages
Punch fixing
Reducing die cutting force by giving taper on
bottom face.

Taper height = h = thickness of sheet.

Taper base length = 200 – 300 mm
 Collar Type Punch
W

1. Height of collar = 2.0 to 2.5 times the width of collar

H = (2.0 to 2.5) x W
2. Collar should be able to bear the load of stripping force.
Height of collar x collar length x shear strength of punch matl > stripping force
 Collar Type Punch
W

1. Height of collar = 2.0 to 2.5 times the width of collar

H = (2.0 to 2.5) x W
2. Collar should be able to bear the load of stripping force.

2 (no of collars) x Height of collar x collar length x shear strength of punch matl >
stripping force
 Compressive load on Top Plate
A
B

Cutting Force
Transferred
to top plate

Cutting Force is transferred to the top plate. This may form a dent or a pit inside the Top
plate. To avoid that the following criteria should be fulfilled:

1. Compressive strength of upper plate x Top end area of punch (A x B) > Cutting force
2. A hardened plate should be provided between the Top plate and punch to distribute
the compressive load over a large area.
3. The top plate should be made of cast iron or any other material with a bigger
compressive strength.
 Stripper Block
When the punch cuts the sheet metal, the sheet that is left on the Die block sticks to the
punch with a lot of force. This sheet metal needs to be separated from the punch for
further operation of the punching.

The stripper block performs the function of separating the raw material and the cutting
punch. The stripper blocks are of the following two kinds:

The stripper block is of two types:

1. Fixed stripper: A part of the lower tool, this is bolted to the die block. This rests
on the Front Gage and rear gage.

2. Floating stripper: This is a part of the Upper Tool. This is attached to the Punch
plate or top plate through either shoulder bolts or through stripper bolts. The stripping
force is provided by the compression springs.

Stripping Force = 5 to 10 % of Cutting Force

Stripper Guide – A floating stripper has to be guided with the help of
guide pins and bushes. However if the blanking punch is big in size, the
floating stripper can be guided on it.
 Stripper Block
Compression Springs
In case of the floating strippers, Compression Springs provide the required stripping force.
Compression springs should never be compressed to their solid length. Suitable spring
guides should be given to prevent side movement and buckling in springs. They should
be uniformly distributed around the blanking punch.

Gas Springs:
When the space is not sufficient to provide the compression springs then Gas springs are
provided. These are gas filled cylinders that operate a piston. They provide higher force
than compression springs. Their stroke length is often greater. They provide almost a
uniform force throughout their stroke length.

Shoulder Bolt or Stripper Bolt: Provided to attach the floating stripper

with the upper tool. A shoulder bolt is one piece bolt whereas a stripper bolt is made up
of a bolt, a cylindrical sleeve and washer.
Fixed Stripper block and Floating stripper
block

Gage
Floating stripper – Open and closed condition
 Other parts of the Blanking Tool
Gages: The gages are rectangular blocks that provide a passage for the movement of the
sheet strip. Their purpose is to guide the strip.

The distance between gages should be equal to strip width plus tolerance on strip width.
Example : If strip width = 100 +/- 2 mm then the distance between gages should be
around 102.5

The height of the gages should be = sheet thickness + height of the fixed stopper + 2-3
mm.

Fixed Stopper: A fixed stopper is fixed to the Die Block. This controls the pitch
of the sheet movement. When the sheet gets punched a hollow is created in that place.
The sheet is moved over the stopper and one side of the hollow is stopped against the
stopper and punching is done.
This is how the pitch is controlled.

Fixed
Stopper
 Other parts of the Blanking Tool
Die Support Plate: This is provided beneath the Die Block. This provides a seat
for the Die Block. This has got an opening in the middle of it for the falling of the blank.
The Die block or Die inserts and housing are bolted on it.

Guide posts and Guide Bushes: These are used for retaining
alignment between upper tool and lower tool. They are two in numbers for smaller tools
and four in numbers for bigger tools. Ball cage type guide pillars are used where cutting
clearances are very small.

Guide Bush

Guide Post

Guide Holder
 Press fit type Guide post and Guide bush

Guide Bush

Press fitted Guide Bush.

Plain Guide Bush press
titted in Upper Plate
Press fitted Guide Post.
Plain Guide Post press
fitted in Lower Plate

Guide Post
 Ball type Guide post and Guide bush

Guide Bush. Fixed to Top

plate

Guide Post with ball

cage and spring

Guide holder fixed to

Bottom Plate
 Question 1
Design a piercing punch for the following part:

Outside dimensions: 200 x 120 x 2.0

Inside dimensions: 150 x 70

Calculate the following:

Piercing Punch length , width, height.

Piercing Force
Stripping force for Piercing
Calculate the collar size also.
Shearing strength for punch = 45 kgf/mm2
Will the collar withstand shearing force?
 Question 2
Design a Blanking Die for the following part:

Outside dimensions: 200 x 120 x 2.0

Inside dimensions: 150 x 70

Calculate the following:

Blanking Die Size

Blanking Punch size
 Questions
1. What is the smallest size of hole that can be pierced on a sheet?
2. What are the ways to reduce the cutting force on a sheet?
3. What is the direction of burr for blank?
4. What is the material of Die Block and hardness?
5. What is the material of gauge?
6. What is the function of a fixed stopper in a Blanking tool?
7. What is cutting clearance? What does it depend upon?
8. A punch has got a collar of thickness T and length = L. The shearing strength of
the punch is 50 kgf/mm2. What is the maximum stripping force that it can
withstand?
9. Calculate the sheet width and advance for the following part. Thickness: 2.0
 Fill in the blanks
1. Die Block is
2. What are the ways to reduce the cutting force on a sheet?
3. What is the direction of burr for blank?
4. What is the material of Die Block and hardness?
5. What is the material of gauge?
6. What is the function of a fixed stopper in a Blanking tool?
7. What is cutting clearance? What does it depend upon?
8. A punch has got a collar of thickness T and length = L. The shearing strength of
the punch is 50 kgf/mm2. What is the maximum stripping force that it can
withstand?
9. Calculate the sheet width and advance for the following part. Thickness: 2.0