‘ EQUIPMENT: TOOLING: PRINCIPLE OF FINEBLANKING Proper fineblanking results are obtained from a specially built fineblanking press with three individual forces. Blanking pressure Counter pressure V-groove (stinger) pressure Highest precision built tooling, similar to a compound die, must match the equipment. The main features are Total of 1%, (of strip thickness) clearance between cutting elements Rounded dieplate edge V-groove (stinger) on guideplate Slugs are ejected into opened die and do not travel through punch as in compound die All cutting elements are straight-walled No dimensional change occurs wit resharpening FINEBLANKING = COLD EXTRUSIONCONVENTIONALLY SHEARED BREAK ~ BURNISHED LAND ROLL OVER (DIEROLL) FINEBLANKED COUNTER PRESSURE BURR SMOOTH EDGE DIE ROLL —__—___—! 2 aFINEBLANKING CYCLE 1 Die is opened. Material ready for 4 Fineblanking cycle completed. bianking, 2 Die closed, material clamped. V-groove impressed in material. 5 Material strip in advanced position. Component is removed by air jet or mechanical arm. Strip 5. Ejector Die Plate G6 Pressure Plate Punch with Stinger Piercing Punch M7 Slug Ejector 3 Part is blanked, while overcoming counter-pressure. —————_§_—a] EDGE CHARACTERISTICS OF A FINEBLANKED COMPONENT A) TAPER DEFINITION The angular accuracy of a fineblanked component is rarely a perfect 90 degree angle in respect to the blanked edge and face of a component. Such an out of square edge is referred to as taper. The dearee of taper is influenced by: Material: - Hardness - Thickness Tooling: Clearance Wear Tool Steel V-groove (stinger) Stability of Die Condition of Cutting Edoe Counter Pressure - V-groove (stinger) Pressure Shape of Part. Lubricant The angular accuracy can be expected within 1 degree. It should be noted that the direction of the taper in a fineblanked component is in the opposite direction of a conventionally sheared stamping (nere referred to as diebreak). Outside contours have a larger degree of taper than internal contours and holes. Taper_can_be reduced by various means in the die, but rarely eliminated without sacrificing in other areas. THE THICKER THE MATERIAL - THE MORE TAPER THE HIGHER THE CARBON - THE MORE TAPER THE MORE ALLOY CONTENT - THE MORE TAPERFINEBLANKED EDGE DIFFERENCE OF OUT OF SQUARENESS BETWEEN FINEBLANKED EDGE AND CONVENTIONALLY STAMPED EDGE. DIEROLL SIDE TAPER | jt + MAXIMUM SMOOTH EDGE CONVENTIONALLY-SHEARED-EDGE DIEBREAK “=Dieroll is the slightly curved contour on the edge of the blanked part created by its movement as it js extruded into the die plate y presents no major problems. However, it may prove dvantage for certain applications, for exanple 7 . gears used in fluid pumps asible in the fineblanking die, dieroll can 2e overcome 1 onal_methods such as grinding. , broaching, etc. two_piece construction may be the wer,for example sprockets, sin dieroli is in direct relatvon to tre material thickness, Harder material also offers a slight reduction in dierol) THE MORE ACUTE THE CORNER - THE MORE DIEROLL THE SMALLER THE CORNER RADIUS - THE MORE DIEROLL THE HARDER THE MATERIAL - THE LESS DIEROLLDIEROLL DEFINITION: eet DIEROLL | | DIEROLL SIDE | 1 cae < , / a BURR SIDEDIEROLL HOLES SMALLER THAN MATERIAL THICKNESS CORNERS ON INSIDE CONTOURS STRAIGHT CONTOURS: CURVED CONTOURS ON LARGE HOLES 90° CORNERS ACUTE CORNERS LESS THAN 90° CITT ITN Dierot! 4-806 612% 15-25% 20-300S- VEERAVEL C) BREAKOUT DEFINITION: Breakout (or fracture) is a burr-side edae condition that is tapered and rough resulting from a shearing effect (like in conventionally stamped parts) caused by too great a clearance between the punch and die. Elimination of breakout is achieved by producing a new punch. D) WAVE DEFINITION: Waves om the sheared surface are caused by a punch/cie clearance which is too smal] and a die plate radius which is too large. Elimination wave is achieved by reworking the punch end regrinding the die plate. BREAK OUT WAVE WAVE AND BREAKOUTTears are a condition of the blanked edge showing asa gap on an interrupted surface. Two types of tears can be distinguished: Corner tears Edge tears Any type of tear is normally undesirable. Corner _tears are occurring on external corners only and never in internal corners. Causes for corner tears: Design: Corner radii too small Material: - Material too hard Material structure not suitable for fineblanking | Too much clearance Tooling: - > Punch worn or chipped Vv - ring defect Dieplate radius too smal] imination of tears is usually achieved by: Using softer material Sharpening die \ . Using a less sharp radius Tightening die clearance 10TEARS CORNER TEAR NO TEARS ON ~ INTERNAL CORNERS J EDGE TEAR /CORNER RADII The extrusion characteristics of fineblanking (rather than shear characteristics) require shar corners to have a blending radius for a smoot uninterrupted flow of the metal during blanking. Corner radii should not be mistaken with "dieroll radius" which appears along the entire sheared surface. There are several distinct types of corners: Radii on external corners - inside contour - outside contour Radii on internal corners - inside contour - outside contour Radii on acute corners Radti on obtuse corners It is imperative to follow the design rules for corner radii to obtein smooth edges on corners without die-tear. There are percent - ratio quidelines to provide maximum punch and die life and no corner tears. Materials not ideal for fineblanking will show corner tears as a First sign Smaller radii can be selected with a sacrifice in tool life or for short runs. Radii on internal contours can even be sharp. THE LARGER THE RADIUS - THE LESS DIEWEAR THE LARGER THE RADIUS THE LESS CORNER TEAR THE LARGER THE RADIUS THE LESS DIEROLL THE HARDER THE MATERIAL - THE LARGER THE RADIUS THE SMALLER THE RADIUS - THE MORE TOOLWEARCORNER RADII DEFINITION OF INTERNAL AND EXTERNAL CORNERS EXTERNAL (inside INTERNAL (inside CORNER contour) CORNER contour) \ — INTERNAL (outside CORNER contour) EXTERNAL (outside CORNER contour) ACUTE OBTUSE CORNER CORNER DESIGN GUIDELINES FOR CORNER RADII 90° CORNER Radius = 10 - 15% of material thickness ACUTE CORNER Radius = 15 - 20% of material thickness A Radius = 5 - 10% of material thickness OBTUSE CORNER R Note: For corners on inside contours use 2/3 of above.NARROW SECTIONS, DIAMETERS AND SLOTS A close or narrow section is the web width between outside contour and inside contour of a component in relation to material thickness. Similar rutes established for sections apply also. for hole dhaneter. shaped internal contours, projections, eetn. Tersile Strength Seczien, Hole Conventional) Fineblanked of material ,Dia., Slot Widty Thickness | Thickness per square inch W Ss | $ 80.000 woe 90.000 Ee closer sections than construction and accuracy rg speed he rar_quides of the fineblarkirg press chieve the smal] a material thickne ratios (50 Ss between reat build ua and specific sheer creased ratios. materials. the above retios cen be jos have to be increased. - similar to dieroll on parts » 21 contours and the o.ts urs between 1 to 10. o* can pe slightly reduces t cannot be eliminatedNARROW SECTIONS, DIAMETERS AND SLOTS SECTIONS IN RELATION TO MATERIAL THICKNESS A) HOLE DIAMETERS. § _, = 100% B) HOLE DIAMETER & SLOT WIDTH eee ds DISHING Fee peer tess i THAN SGEAR TEETH, NARROW PROTRUSIONS AND TABS GEAR TEETH can often be cost effectively fineblanked. The relationship between the width of the gear tooth (W) and the material thickness (S) is similar to that of narrow sections. The width of the tooth at the pitch diameter is generally limited to 60. of the material thickness. If the width/thickness ratio must be less, then laminating two gear blanks may be considered. Since the Jaminated oe includes two pieces, the width/thickness ratio is cut in half Lower tensile strength material generally allows. the tooth width/material thickness ratio to be reduced, thereby allowing more teeth. Material with higher tensile. nsile strength requires a wider tooth in relationship to the material thickness. The tooth form also affects the guideline for the width/thickness ratio, Generally the deeper the tooth, the wider the tooth must be in relationship to the material thickness. Also the radius (R) of the tooth crest and root form must be suificiently Pounded to avoid tears (refer to section on Corner Radi). Die roll on gear teeth is generally greater than that on typical outside contour, due to the narrow radius of a gear tooth. This die roll, however, may eliminate the need to bevel the teeth. OW PROTRUSIONS exist when the width of a ae on an ide contour approaches the thickness the material. Generally the width 1s limited to 67% of the material thickness. id slots likewise are subject to guidelines which include the tab or slot width (Ww) and depth (D) to material thickness (S). Generally if the depth of the tab or slot is less than masecia thickness, then the tab or Slot width can de as narrow as 16