Data given:

The material is Aluminium Alloy 2024.

Shearing strength 16000 psi.
The punch’s have 0.050 inch. shear.
The sheet size 4 feet. x 8 feet. (1 feet. = 12 inch.)

Wide-run

Design the strip layout for a narrow run

Step1: Strip layout: Single row single pass (narrow run)

Sheet available has a size 0.03 𝑖𝑛.× 48 𝑖𝑛.× 96 𝑖𝑛. Narrow-run

The position of H and I depend on orientation of part
Size of blank (in vertical direction) 1.125 𝑖𝑛. (𝐻) on the strip
Remember:
𝑩 = 𝟏. 𝟐𝟓 × 𝑻 ; 𝒘𝒉𝒆𝒏 𝑪 𝒊𝒔 𝒍𝒆𝒔𝒔 𝒕𝒉𝒂𝒏 𝟐 𝒊𝒏.
𝑩 = 𝟏. 𝟓𝟎 × 𝑻 ; 𝒘𝒉𝒆𝒏 𝑪 𝒊𝒔 𝒎𝒐𝒓𝒆 𝒕𝒉𝒂𝒏 𝟐 𝒊𝒏.

Assume the bridge gap (B)= 1.50 × 𝑇 (𝑤ℎ𝑒𝑛 𝐶 𝑖𝑠 𝑚𝑜𝑟𝑒 𝑡ℎ𝑎𝑛 2 𝑖𝑛. )
= 1.50 × 0.03𝑖𝑛
= 0.045 𝑖𝑛.
Width of the strip (W) required for one blank:
𝑊 = 0.045 + 1.125 + 0.045
𝑊 = 1.215 𝑖𝑛.

Step 2: The number of strips that can be cut from one sheet
48 𝑖𝑛.
= 39.51 ≈ 𝟑𝟗 𝒔𝒕𝒓𝒊𝒑𝒔
1.215 𝑖𝑛.

Step 3: Number of blanks per strip

𝐶 = 𝐼+𝐵
𝐶 = 3.50 𝑖𝑛. +0.045 𝑖𝑛. = 3.545 𝑖𝑛.
𝐿−𝐵
𝑁=
𝐶
 96 − 0.045
𝑁= = 27.07 ≈ 𝟐𝟕 𝒃𝒍𝒂𝒏𝒌𝒔
3.545

Step 4: Number of blanks per sheet

= 39 × 27 = 𝟏𝟎𝟓𝟑 𝒃𝒍𝒂𝒏𝒌𝒔

Step 5: Determine the area of unused strip

Y=0.6005
1.125
𝐻= = 1.299 𝑖𝑛.
sin 60
1.125 H=1.299
𝑋 = 1.299 cos 60

𝑋 = 0.6495 𝑖𝑛.
X = 0.6495
𝑌 = 1.25 − 0.64955

𝑌 = 0.6005 𝑖𝑛.

Area of one blank:

1 𝜋
= (1.125 × 1.25) + (0.625 × 1) + ( (1.25 + 0.601) × 1.125) − ( × 12 )
2 4

= (1.406 + 0.625 + 1.041) − (0.786)

= 2.286 𝑖𝑛.2

If 𝐴 = 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑠𝑡𝑎𝑟𝑡𝑖𝑛𝑔 𝑠𝑡𝑟𝑖𝑝; 𝐵 = 𝑡𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑏𝑙𝑎𝑛𝑘 𝑐𝑢𝑡

∴ 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑢𝑛𝑢𝑠𝑒𝑑 𝑠𝑡𝑟𝑖𝑝 = 𝐴 − 𝐵

𝐴 = 96 × 1.215 = 116.64 𝑖𝑛.2

𝐵 = 27 × 2.286 = 61.72 𝑖𝑛.2
𝐴 − 𝐵 = 𝟓𝟒. 𝟗𝟐 𝒊𝒏.𝟐

Step 6: Determine % of scrap

𝐴−𝐵
% 𝑜𝑓 𝑠𝑐𝑟𝑎𝑝 = × 100
𝐴
54.92
= × 100 = 𝟒𝟕. 𝟎𝟗%
116.64

Step 7: Determine % of utilization

𝐵
% 𝑜𝑓 𝑢𝑡𝑖𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 = × 100
𝐴
61.72
= × 100 = 𝟓𝟐. 𝟗𝟏%
116.64
 The required punching and stripping force (with consider shear force).

Forces for Piercing Operation

Step 1: Punches are staggered Remarks:

𝐿 × 𝑡 × 𝑆𝑆 𝐹 = 𝑓𝑜𝑟𝑐𝑒; 𝑡𝑜𝑛𝑠
𝐹= 𝐿 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡 𝑒𝑑𝑔𝑒; 𝑖𝑛
2000 𝑡 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙; 𝑖𝑛
𝑆𝑠 = 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ; 𝑝𝑠𝑖 𝑜𝑟 (𝐼𝑏⁄𝑖𝑛2)
(𝜋𝐷) × 𝑡 × 𝑆𝑆
= *Conversion
2000 1 𝐼𝑏 = 0.0005 𝑡𝑜𝑛𝑠 (𝑈𝑆 𝑡𝑜𝑛)𝑜𝑟
(𝜋1.0) × 0.03 × 16000 = 1⁄2000 𝑡𝑜𝑛𝑠
= = 𝟎. 𝟕𝟓𝟒 𝒕𝒐𝒏𝒔
2000

Step 2: Determine punch force with consider sheared force.

Punches are staggered Remarks:
𝐹𝑠 = 𝑓𝑜𝑟𝑐𝑒 𝑜𝑓 𝑠ℎ𝑒𝑎𝑟𝑒𝑑 𝑝𝑢𝑛𝑐ℎ; 𝑡𝑜𝑛𝑠
𝐹𝑆 = 𝐾 × 𝐹 𝐹 = 𝑓𝑜𝑟𝑐𝑒; 𝑡𝑜𝑛𝑠
𝐾 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡
𝑡×𝑝 (0.03 × 0.6) 𝑝 = % 𝑝𝑒𝑛𝑒𝑡𝑟𝑎𝑡𝑖𝑜𝑛
𝐾= = = 0.36 𝑡 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠; 𝑖𝑛.
𝑠 0.05 𝑠 = 𝑠ℎ𝑒𝑎𝑟; 𝑖𝑛.

*Table: % of penetration
𝐹𝑆 = 0.36 × 0.754 = 𝟎. 𝟐𝟕𝟏 𝒕𝒐𝒏𝒔

Step 3: Stripping force

Remarks:
𝑓𝑠 = 𝑠𝑡𝑟𝑖𝑝𝑝𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒; 𝐼𝑏
𝑓𝑠 = 3500 × 𝐿 × 𝑡 𝐿 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡 𝑒𝑑𝑔𝑒; 𝑖𝑛
𝑡 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠; 𝑖𝑛.
𝑓𝑠 = 3500 × (𝜋𝐷) × 𝑡

𝑓𝑠 = 3500 × (𝜋 × 1.0) × 0.03 = 329.87 𝐼𝑏 or 329.87 × 0.0005 𝑡𝑜𝑛𝑠 = 𝟎. 𝟏𝟔𝟓 𝒕𝒐𝒏𝒔

Additional:
𝐹𝑇 = 𝐹𝑆 + 𝑓𝑆

Total force required:

𝐹𝑇 = 0.27 + 0.165 = 𝟎. 𝟒𝟑𝟓 𝒕𝒐𝒏𝒔
Press tonnage/capacity
0.435
= 𝟎. 𝟔𝟐 𝒕𝒐𝒏𝒔
0.7
Forces for Blanking Operation

Step 1: Punches are staggered

𝐿 = 1.125 + 1.25(2) + 1(2) + 1.25 + 1.299 + 0.6005 + 0.25(4) = 9.775 𝑖𝑛.

𝐿 × 𝑡 × 𝑆𝑆 Remarks:
𝐹= 𝐹 = 𝑓𝑜𝑟𝑐𝑒; 𝑡𝑜𝑛𝑠
2000 𝐿 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡 𝑒𝑑𝑔𝑒; 𝑖𝑛
𝑡 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙; 𝑖𝑛
9.775 × 0.03 × 16000 𝑆𝑠 = 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ; 𝑝𝑠𝑖 𝑜𝑟 (𝐼𝑏⁄𝑖𝑛2)
= = 𝟐. 𝟑𝟒 𝒕𝒐𝒏𝒔
2000 *Conversion
1 𝐼𝑏 = 0.0005 𝑡𝑜𝑛𝑠 (𝑈𝑆 𝑡𝑜𝑛)𝑜𝑟
= 1⁄2000 𝑡𝑜𝑛𝑠

Step 2: Determine punch force with consider sheared force.

Punches are staggered
𝐹𝑆 = 𝐾 × 𝐹
Remarks:
𝐹𝑠 = 𝑓𝑜𝑟𝑐𝑒 𝑜𝑓 𝑠ℎ𝑒𝑎𝑟𝑒𝑑 𝑝𝑢𝑛𝑐ℎ; 𝑡𝑜𝑛𝑠
𝑡×𝑝 (0.03 × 0.6) 𝐹 = 𝑓𝑜𝑟𝑐𝑒; 𝑡𝑜𝑛𝑠
𝐾= = = 0.36 𝐾 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡
𝑠 0.05 𝑝 = % 𝑝𝑒𝑛𝑒𝑡𝑟𝑎𝑡𝑖𝑜𝑛
𝑡 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠; 𝑖𝑛.
𝐹𝑆 = 0.36 × 2.34 = 𝟎. 𝟖𝟒 𝒕𝒐𝒏𝒔 𝑠 = 𝑠ℎ𝑒𝑎𝑟; 𝑖𝑛.

*Table: % of penetration

Step 3: Stripping force Remarks:

𝑓𝑠 = 𝑠𝑡𝑟𝑖𝑝𝑝𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒; 𝐼𝑏
𝐿 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑢𝑡 𝑒𝑑𝑔𝑒; 𝑖𝑛
𝑓𝑠 = 3500 × 𝐿 × 𝑡 𝑡 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠; 𝑖𝑛.

𝑓𝑠 = 3500 × 9.775 × 0.03 = 1026.38 𝐼𝑏 or 1026.38 × 0.0005 𝑡𝑜𝑛𝑠 = 𝟎. 𝟓𝟏 𝒕𝒐𝒏𝒔

Additional:
𝐹𝑇 = 𝐹𝑆 + 𝑓𝑆
Total force required:
𝐹𝑇 = 0.84 + 0.51 = 𝟏. 𝟑𝟓 𝒕𝒐𝒏𝒔
Press tonnage/capacity
1.35
= 𝟏. 𝟗𝟑 𝒕𝒐𝒏𝒔
0.7
 The required tool dimension for punch and die opening

Designing tools dimension of punch and opening die required Clearance is the space between the punch and the
die. It is significantly effect on dimension
accuracy during blanking and piercing process.
L6

L5
L1

L2 L3
L4

Step 1: Identify the material of part. Refer ‘Table: Clearance allowance’, take value of their
clearance allowance

Material: Aluminium Alloy 2024; a = 6.0 % or 0.06

Clearance (at one side); 𝒄 = 𝒂 × 𝒕
𝑐 = 0.06 × 0.030 𝑖𝑛. = 0.0018 𝑖𝑛.

The general rule for the application of clearances is follows:

The size of the punch determines the size of the pierced hole. The size of the die opening determines the size of the
blanked part.

Notes: Recovery behaviour of material punched: May cause the hole size smaller than the punch with produced it. While, when a
part is blanked in press, may cause the blanked part is larger than the die opening which produced it. Normally, 0.002 in. @ 0.050
mm. taken as an allowance for a round punch and die. If punch is not round, 0.001 in. @ 0.025 mm. may be used .

Step 2: Rule size of hole is determined by punch size. The hole will shrink approximate 0.002 in.
Hence, the punch size:
𝑃𝑃 = 1 + 0.002 = 1.002 𝑖𝑛.
Remarks:
𝑃𝑃 = 𝑝𝑖𝑒𝑟𝑐𝑖𝑛𝑔 𝑝𝑢𝑛𝑐ℎ

Step 3: The piercing die opening will need to be larger than the punch.

𝑫𝑷 = 𝑷𝑷 + 𝟐𝒄
𝐷𝑃 = 1.002 + 2(0.0018) = 1.0056 𝑖𝑛.
Remarks:
𝑃𝑃 = 𝑝𝑖𝑒𝑟𝑐𝑖𝑛𝑔 𝑝𝑢𝑛𝑐ℎ
𝐷𝑃 = 𝑝𝑖𝑒𝑟𝑐𝑖𝑛𝑔 𝑑𝑖𝑒 𝑜𝑝𝑒𝑛𝑖𝑛𝑔
 The general rule for the application of clearances is follows:
The size of the punch determines the size of the pierced hole. The size of the die opening determines the size of the
blanked part.

Notes: Recovery behaviour of material punched: May cause the hole size smaller than the punch with produced it. While, when a
part is blanked in press, may cause the blanked part is larger than the die opening which produced it. Normally, 0.002 in. @ 0.050
mm. taken as an allowance for a round punch and die. If punch is not round, 0.001 in. @ 0.025 mm. may be used .

Step 4: Rule size of the blank is determined by the blanking die opening. The part dimension will
expand approximately 0.001in. Hence, the die opening size:

Remarks:
𝐷𝑏 = 𝑏𝑙𝑎𝑛𝑘𝑖𝑛𝑔 𝑑𝑖𝑒 𝑜𝑝𝑒𝑛𝑖𝑛𝑔

L1
𝐷𝑏(𝐿1) = 1.125 − 0.001 = 1.124 𝑖𝑛.

L2
𝐷𝑏(𝐿2 𝑢𝑝𝑝𝑒𝑟) = 1.25 − 0.001 = 1.249 𝑖𝑛.
𝐷𝑏(𝐿2 𝑙𝑜𝑤𝑒𝑟) = 1.25 − 0.001 = 1.249 𝑖𝑛.

L3
𝐷𝑏(𝐿3 𝑢𝑝𝑝𝑒𝑟) = 1.0 − 0.001 = 0.999 𝑖𝑛.
𝐷𝑏(𝐿3 𝑙𝑜𝑤𝑒𝑟) = 1.0 − 0.001 = 0.999 𝑖𝑛.
L4
𝐷𝑏(𝐿4) = 1.25 − 0.001 = 1.249 𝑖𝑛.

L5
𝐷𝑏(𝐿5) = 1.299 − 0.001 = 1.298 𝑖𝑛.

L6
𝐷𝑏(𝐿6) = 0.6005 − 0.001 = 0.5995 𝑖𝑛.

Step 5: Determine the blanking punch size according value 𝐷𝑏 and allowance clearance of material
𝐷𝑏 = 𝑃𝑏 + 2𝑐
𝑃𝑏 = 𝐷𝑏 − 2𝑐

Remarks:
𝑃𝑏 = 𝑏𝑙𝑎𝑛𝑘𝑖𝑛𝑔 𝑝𝑢𝑛𝑐ℎ

L1
𝑃𝑏(𝐿1) = 1.124 − 2(0.0018) = 1.1204 𝑖𝑛.

L2
𝑃𝑏(𝐿2 𝑢𝑝𝑝𝑒𝑟) = 1.249 − 2(0.0018) = 1.2454 𝑖𝑛.
𝑃𝑏(𝐿2 𝑙𝑜𝑤𝑒𝑟) = 1.249 − 2(0.0018) = 1.2454𝑖𝑛.
L3
𝑃𝑏(𝐿3 𝑢𝑝𝑝𝑒𝑟) = 0.999 − 2(0.0018) = 0.9963 𝑖𝑛.
𝑃𝑏(𝐿3 𝑙𝑜𝑤𝑒𝑟) = 0.999 − 2(0.0018) = 0.9963 𝑖𝑛.

L4
𝑃𝑏(𝐿4) = 1.249 − 2(0.0018) = 1.2454𝑛.

L5
𝑃𝑏(𝐿5) = 1.298 − 2(0.0018) = 1.2944 𝑖𝑛.

L6
𝑃𝑏(𝐿6) = 0.5995 − 2(0.0018) = 0.5959 𝑖𝑛.

ooOOoo

Last update: 7/6/2023-Prepared by: DR. Mohd Azaman Md Deros

For my beloved student

 Table: % of penetration

Table: Clearance allowance

Material Clearance Allowance

(%)
1100S and 5052S aluminium 4.5
alloys; all tempers
2024ST and 6061ST 6.0
aluminium alloys; soft cold
rolled steel; soft stainless
steel; annealing steel
half hard cold rolled steel; 7.5
half hard and full hard
stainless steel

Normally, 0.002 inch @ 0.050 mm taken as an allowance for a round punch and die. If punch and
die are not round, 0.001 inch @ 0.025 mm may be used, Conversions unit: 1 𝑁 = 0.000102 𝑡𝑜𝑛𝑠