Basic Punching Theory: ©2008 Mate Precision Tooling

Basic Punching Theory
©2008 Mate Precision Tooling

1
The ‘BIG 3’ Problems
• Die clearance too small

• Poor or no maintenance on the tool
• Turret alignment requires adjustment

Basic Hole Punching Theory
 Punching a hole
 Die Clearance
 Punch Tonnage
 Choosing the right tool
 Correct tool maintenance
…

Punching Cycle
Impact Penetration
Punch Roll-over
Material
Die
Fracture (@ 30% t) Stripping

Burnish
Fracture
zone
 Slug to go approx. 3 mm into

die
for slug free dies
Punch force diagram
Cross Section of a
Quality Hole
Slug
 Burr height graphs


Proper vs. Tight Clearance

Proper vs. Tight Clearance
Fracture lines meet
- Punching forces are balanced,

- Maximum piece part quality and
tool life
Fracture lines do not meet
- Secondary shear cracks,

- Extra energy required,
- Higher tool wear (dies wear quicker)
Extra energy does not disappear,

but is converted into heat !!

Excessive Clearance
More Rollover & Less Burnish zone
Tool lasts longer !

Large Burr, not compressed
and can be removed easily

Proper Die Clearance
Material Type Material Piercing Total Blanking Total Die
Shear Strength Thickness Die Clearance % Clearance %
Aluminum Less 2.5mm 15% 15%
22 –25 kp/mm² 2.5mm to 5.0mm 20% 15%
Greater than 5.0mm
25% 20%
Mild Steel Less than 3.0mm 20% 15%
3.0mm to 6.0mm
40 kp/mm² 25% 20%
Greater than 6.0mm
30% 20%
Stainless Steel Less than 1.5mm 20% 15%
60 kp/mm² 1.5mm to 2.8mm 25% 20%
2.8mm to 4.0mm
30% 20%
Greater than 4.0mm
35% 25%
Note: 1) In general: shear strength determines clearance

(10% is already good for low shear strength aluminium)
2) Minimum die clearance recommended : 0.08 mm
Improper Die
Clearance

Piercing vs. Blanking
Piercing
– The slug is scrap. The interior of the sheet is
the product.
– Depending on the tool design, more than one
hole can be punched at one time. Cluster
tools for example.
– In piercing operations, the die clearance is
calculated from the punch size.

12
Piercing vs. Blanking
Blanking
– The punched item is of value. The slug is
important.
– Special shapes are used mostly in blanking
operations.
– Blanking operations calculate the die
clearance from the desired blank dimensions.

13
Punching Techniques
Blanking
– When the
slug
becomes
the “good”
or the
“saved
part”

14
Punching Techniques
Blanking rather than
punching can save
time, tool life and
sheet usage

15
Ordering Punches and
Dies
Piercing a Hole Blanking a Part
Punch Size = Die Size =

Desired Hole Size Desired Blank Size
(no Slug Free dies !)
Die Size =
Punch Size + Punch Size =
Total Clearance Die Size – Total Clearance

Tonnage
calculation
F (tons) = P x t x S / 1000
Required Punch Tonnage (tons) =

hole perimeter (mm) * material thickness (mm) * shear factor (kpmm²)
1000
Some important shear factors (σ): Aluminium 22 -25kp/mm2

Mild Steel 40 kp/mm2
Stainless Steel 60 kp/mm2
Cluster tools : multiply by
number of punches
Tonnage reduction by ‘step’-
punching: step = ½ material Note : try not to exceed 80% of punch
thickness press capacity

Tonnage calculation
Material shear factors ( σ ) :

Aluminum = 22-25 kp/mm2
Mild steel = 40 kp / mm2
Stainless steel = 60 kp /mm2
18
18
Tonnage
calculation
Ø 30mm hole
Material shear factors ( σ ) :

Aluminum = 22-25 kp/mm2
Mild steel = 40 kp / mm2
Stainless steel = 60 kp /mm2
3mm stainless steel
Formula: Tonnage =
hole perimeter (mm) * material thickness (mm) * shear factor (kpmm²)

1000
Example: Ø 30mm hole in 3mm stainless steel

Tonnage = (30 x 3.14) x 3 x 60 = 16,96 t
1000
 Keep in mind : Stripping springs !
 Required Tonnage + Stripping Force

must be Tonnage to be within Machine Capacity !
Perimeter Calculations
A = Diagonal Dimension
(Station Size)
L = Hole Perimeter
Calculate diagonals to
determine station size
Calculate perimeters for

tonnage calculations

 Calculator program for Clearance / Tonnage / Station Size

Use of Shear on
Punches • Shear typically 1.5 – 2 mm
• Max up to 80% of machine
capacity
• Shear punches need sharp
edges (sharpen frequently)
• Best shear is rooftop; use

min. 75-80% of length; can
be used at high tonnage
• Concave shear: inverts
stresses, good alternative
for nibbling; max 15 Ton
• One-way: good blanking
shear
• Four-way: very good on
squares; hard to regrind
• Trumpf ‘Whisper’ very
good, but hard to regrind
• Cup shear on rounds (Tr)

Punch Shear Examples
Four-Way Concave Rooftop
One-way & Whisper Cup

Advantages of Shear
Tonnage reduction
Noise reduction
Slug control
Reduced shock loads on the machine
Flatter sheets
Improved stripping
Increased tool life

Treated Punches
Please note!
Nitrated punches not recommended for diameter or width less than 6 mm !!
Treatment vs. Coating
Nitride Treatment
Nitriding is a heat treatment feature for HSS punches.
Punches are more wear resistant, but also more brittle (esp. during stripping).
Recommended for materials that cause galling, such as stainless steel, galvanized steel,
or aluminum, but not if the material is too thick, as stripping might cause chipping.
Can also be used for mild steel, will increase tool life (up to 4x).
Also recommended for punching abrasive materials such as fiberglass.
It is not recommended for punches smaller than 6mm in diameter or width, as punch is too
brittle and may chip off.
Maxima® Coating
Maxima is a hard, wear-resistant, multilayer Zirconium Titanium Nitride (ZrTiN) coating,
It puts a hard surface on the punch, adds wear resistance and ‘lubricates’ the process.
The coating acts as a barrier between the punch and the sheet metal being punched.
Its exceptional lubricity, reduces the friction that occurs during the stripping portion of the
punching cycle, thus especially recommended in thicker material.
Less friction means less heat build up, less galling and longer tool life.
Also recommended upon high use of the punch, or as a problem solver.
 Maxima Coating is more expensive than Nitride Treatment.

Treatment vs. Coating

Mate Slug Free ® Die
Slug Free® Die Components
1. Punch
2. Stripper
3. Material
4. Slug Free® Die
5. Slug
6. Grind Life
7. Entry -- Constricting Taper 0.5°
8. Pressure Point (at specific depth (*))
9. Exit -- Relief Taper 5.0°
Hole/Slug Geometry
A. Rollover
B. Burnish
(*) depth = 1.5 mm + 0.7 * thickness C. Fracture
(max = 3.0 mm)
D. Burr
Slug Free ® Die Detail
Stripper
Punch
Material
Material held Penetration begins Material begins to

Slug Free Die ® securely by stripper and metal deforms fracture at stress points
before punch makes into the entry taper
contact
Slug fractures Pressure point Punch stroke bottoms Punch retracts and
away from sheet constricts slug out as slug squeezes slug is free to fall down
past pressure point and away through exit
taper

Uniform Clearance
Dies
-No corner burrs with

Constant Clearance
in shaped die corners
-Stress relief in die
corners

Uniform Clearance
Dies
Corner burrs when non-uniform

clearance dies are used

Slug Free Light ®
Optional Die Land to prevent slug-
pulling in problem materials or
extremely thin material.
Blips 0,05mm deep are cut into the die
wall to allow the slug to expand into
the slots. Blips act as mechanical
locks to trap the slug.
Material Type Recommended

Material Maximum
Stainless Steel 0.80mm

Especially for bigger
Mild Steel 1.00mm
diameters and thin material
(max. 1,5 mm). Aluminum 1.20mm

Standard Back-taper
1/8 degree per side

(1/4 degree TOTAL)
Punch Size
Heavy Duty Back-
taper
Recommended when punching force over 18 tons
and/or thickness above 4 mm
1 degree per side

(2 degrees TOTAL)
Punch Size
Punching Thick Material
(>4mm)
When ordering tools:
• HD tool configuration (Rooftop punch with extra
Backtaper)
• Clearance of 25-30% of Material Thickness
• 0.5mm radius on all punch corners
• Punch to material thickness ratio of 1 minimum
When punching:
• Lubricate the sheet / punch / guide
• Run Machine on slow cycle
• Inspect tools frequently for wear / Use sharp Punches &
Dies

Punching Thick Material
(>4mm)
Common Poblems / Solutions
•Stripping problems
HD configuration – Lubrication – Coating on punch –
Use bigger station – Gas canister
•Excessive tonnage / High tool wear / High vibrations

Make sure tonnage calculation is correct –
Use Lubrication – Sharp tools – HD configuration –
Maxima coating – Shear on punch – Correct die
clearance – Pre-pierce holes – Bridge hitting
•Work piece distortion/stretching

Change punch pattern (bridge hitting) – Slow down
machine – Use Fully Guided – Sharpen tools

Slitting Tip
Bridge Hitting
As consecutive nibbling may cause unbalanced forces,
apply bridge hitting to avoid side loading during slitting
operations:

Large Holes Without Exceeding
Press Tonnage
The customer wants to pierce a 50.0mm dia. hole in thick mild steel.
He does not want to buy a special shape radius tool, but wants to use
standard tooling.
Tool 2 Finalize the hole

with a 50mm flat punch
Tool 1 Use one
Square 10mm and 8 hits 10mm sq..
pre-pierce along the
50mm periphery 8
holes with equal
pitch.
Final Hit 50mm
round

Punching Thin Material (<1mm)
When ordering tools:

You may require
• Ultra Light canisters
• Light shear on punches
• Fully Guided guide/stripper solution
• Urethane stripper pads
• Slug Free Light dies
When punching:
• Run Machine on slower cycle
• Inspect tools frequently for wear
• Use sharp punches & dies

Punching Thin Material (<1mm)
Common Poblems / Solutions
•Sheet marking
Urethane stripper pads – Ultra Light
•Slug pulling
Maximize die penetration – Demagnetise tools – Slug
Free Light – Correct die clearance – Slug ejectors –
Shear on punch
•High tool wear due to small clearance

Maintain turret alignment
•Work piece distortion/stretching

Change punch pattern – Slow down machine –
Sharpen tools – Use Fully Guided

Punching non-metallic
material
Use concave shear punches
Use Maxima or Nitride punches
Reduce die clearance with 5 %
Use sharp punches and dies

Run the machine on a slower cycle
Lubricate hard plastics if possible
Use urethane pads if marking occurs
Support thin material if needed

‘Shaving’ – Make Straight Walled
Holes Without Drilling
Finished hole size is the starting point.

Punch #1 = finished hole size – clearance (20%)
Die #1 = finished hole size + 0.1 mm
Punch #2 = finished hole size (full mat’l contact : Maxima !)
Die #2 = die #1
.

Preventing Slug
Pulling
Use Slug Free® Dies
Eliminate Magnetism In Tools
Lightly Dull Recently Sharpened Tools (with oil stone)
Decrease Die Clearance
Maximize Die Penetration
Use Shear on Punches
Use Urethane Slug Ejectors (need replacement !)

Overcoming Stripping
Problems
Use Sharp Punches & Dies
Lubricate Sheets
Remove Galling
Check Stripping Springs For Fatigue
Use Additional Back-Taper on Punches

Increase Die Clearance
Use HD Tool Configurations
With Spring Tooling Use Larger Station

Galling
Galling is an adhesion to the punch
tip by the metal being punched,
caused by pressure and heat.
The best technique for removing galling
is to rub it off with a fine stone. The
rubbing should be done parallel to the
direction of the punching motion. This
will polish the surface that contacts the
material, decreasing any chance of
future galling. Do not sandblast, belt
sand or use other harsh abrasive
methods. These create a coarse
surface finish to which material adheres
more easily.

Reduce Galling
Use sharp Punches & Dies
Lubricate Work Piece
Adjust Machine Hit Rate (Slower)
Use ABS If Available (Tool Lubrication)
Increase Die Clearance

Use Maxima or Nitride
Treated Punch

Small Diameter or
Narrow Holes
When punching small diameter or narrow holes,
maintain the following ratio of punch size (minimum)
to material thickness:
Material Punch to Material Ratio
Aluminum 0.75 to 1
Mild Steel 1 to 1
Stainless Steel 2 to 1

Small Diameter or
Narrow Holes
With Fully Guided
Material Punch to Material Ratio
Aluminum 0.75 to 1 (Fully Guided 0.5 to 1)
Mild Steel 1 to 1 (Fully Guided 0.75 to 1)
Stainless Steel 2 to 1 (Fully Guided 1 to 1)

Minimum Spacing
Between Holes and
Forms
Top view of sheet
To avoid hole distortion:
Minimum = 2 x Material Thickness between holes
Minimum = 2 1/2 x Material Thickness to sheet edge

Minimum Spacing
Between Holes and
Forms
Spacing between forms
Minimum = 2 1/2 x Material Thickness to sheet edge

Nibbling
Nibbling
– Minimum feed rate is equal
to material thickness.

Nibbling
Nibbling is not
always
recommended
…
Excessive Nibbling
Nibbling patterns can be
done with much less hits
with a banana tool or multi-
radius tool
(with tool rotation)

54
Punching Tip
Combating Warpage
To avoid sheet warpage when

punching multiple holes,
punch every other hole first,
then come back

Cluster Tools
In order to reduce noise ,
vibrations and tonnage on
cluster tools it is
recommended to shorten 50
% of the cluster punches with
about 50 – 60% of the sheet –
thickness.
Example:
Cluster of 16 x square 10mm
Perforating in 1mm mild steel
Insert Punch length 37mm
Shorten 8 Punches to length
36,5mm ( Balanced Shortening)

Blanking Operations
Blanking --
When the slug

becomes the
“good” or the
“saved part”

Blanking Operations
•Blanking rather than
punching can save
time, tool life and
sheet usage …
•Special shapes can

be done with a
combination of
standard tooling

Blanking Operations
Extremely sharp punches and dies
Reduce die clearance by 5%
Determine which blank dimensions & tolerances are critical
Notify tooling provider that tooling required will be used for
blanking
Use non-slug free or straight taper dies
Punches should be flat faced or with slight one-way shear
Frequently inspect tools for wear
Note: Be aware of the changing of burr side when

piercing and blanking is combined.

Blanking Punch
Configuration
3.0-5.0mm flat
Punch
1.5-3.0 degree one-way shear

can be used
Note: Shear punches give flatter workpieces
©1999 Mate Precision

©2008 Tooling Tooling
Mate Precision
• Poor or no maintenance on the

tool

P u n c h s e c t io n Sheet :
w it h d u ll e d g e
R o ll- o v e r
S lu g :
S t r a ig h t w a ll
B u rr
F ra c tu re b e tw e e n
p la t e a n d s lu g
S t r a ig h t w a ll
R o ll- o v e r
B u rr
D ie s e c t io n
w it h d u ll e d g e
Close-up of a burr
When to Grind ?
Recognize dull
tools
Sharpen
when a
0.25 mm
radius
forms on
the punch
R = 0.25mm
or the die
- When the cutting edge shines
- When hole quality changes
- When the sound of punching changes

How much to Grind ?
Calculating grind
life
Stripper Land
- Ultra A-B = 4 mm
- Ultra C-D-E = 8 mm
Material Thickness
Die Penetration
Usable Grind Life
Grind Life = SBR - (Stripper Thickness + Material Thickness + Die Penetration)

Max. SBR
Thickness Ultra
Punches have a bigger grind life A 3,8 18,9
in smaller thickness B 6,4 18,9
©2008 Mate Precision Tooling C-D-E 6,4 25,5
How frequent to Grind
? Importance of frequent grinding
Improper Sharpening Proper Sharpening

Total Holes Radius Total Holes Radius
Produced Formed Produced Formed
100,000 0.25mm 100,000 0.25mm
50,000 0.50mm 100,000 0.25mm
25,000 0.75mm 100,000 0.25mm
10,000 1.00mm 100,000 0.25mm
185,000 1.0mm 400,000 1.0mm
Total Hits Total Removed Total Hits Total Removed
More than DOUBLE the tool life when sharpened frequently!

How to Grind ? Sharpening Rules
Sharpen frequently
 Shear punches to be
reground more often
than flat punches
Use coolant
Correct wheel parameters
Demagnetize all tooling after
regrinding
Break edges with oil stone

Sharpening
Excellent sharpening results

IMPORTANCE OF CORRECT
MAINTENANCE :
bad sharpening
practices

68
Benefits of Proper
Tool Maintenance
Flatter sheets
(Note: Shear punches give flatter sheets)
Cleaner holes
Less stress on tool and machine
Longer tool life
 Maxima coating not affected

Maximizing Tool Life
Sharpen frequently
Use proper die clearance
Use proper shear configuration
Lubricate punch, guide and sheet
Inspect tool holders for wear
Use treated tools for special applications
Use radii on all sharp corners
Demagnetize all tooling after regrinding
Check turret alignment regularly


• Turret alignment requires

adjustment

Thick Turret Alignment Tools
Mate PILOT
Alignment System
Standard Alignment tool

PILOT Alignment
Tool

PILOT Alignment
Tool

Mate PILOT
Indicator light color :

– Red – not aligned
– Yellow – aligned within
0.0012 (0.030)
– Green - aligned within
0.0003 (0.008)

Mate PILOT
Loosen upper and

lower tool holder
retaining screws

Mate PILOT
Station Alignment to machine
– alignment bar and dial-indicator

Questions?

u !
y o
n k
a
Th

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Basic Punching Theory

©2008 Mate Precision Tooling

• Die clearance too small

©2008 Mate Precision Tooling

©2008 Mate Precision Tooling

Fracture (@ 30% t) Stripping

 Slug to go approx. 3 mm into

• Die clearance too small

©2008 Mate Precision Tooling

©2008 Mate Precision Tooling

- Punching forces are balanced,

Fracture lines do not meet

- Secondary shear cracks,

Extra energy does not disappear,

©2008 Mate Precision Tooling

More Rollover & Less Burnish zone

Tool lasts longer !

©2008 Mate Precision Tooling

Note: 1) In general: shear strength determines clearance

©2008 Mate Precision Tooling

©2008 Mate Precision Tooling

©2008 Mate Precision Tooling

©2008 Mate Precision Tooling

©2008 Mate Precision Tooling

Punch Size = Die Size =

©2008 Mate Precision Tooling

Required Punch Tonnage (tons) =

Some important shear factors (σ): Aluminium 22 -25kp/mm2

©2008 Mate Precision Tooling

Material shear factors ( σ ) :

Material shear factors ( σ ) :

hole perimeter (mm) * material thickness (mm) * shear factor (kpmm²)

Example: Ø 30mm hole in 3mm stainless steel

 Required Tonnage + Stripping Force

Calculate perimeters for

©2008 Mate Precision Tooling

©2008 Mate Precision Tooling

• Best shear is rooftop; use

©2008 Mate Precision Tooling

One-way & Whisper Cup

©2008 Mate Precision Tooling

©2008 Mate Precision Tooling

 Maxima Coating is more expensive than Nitride Treatment.

©2008 Mate Precision Tooling

©2008 Mate Precision Tooling

Material held Penetration begins Material begins to

©2008 Mate Precision Tooling

-No corner burrs with

©2008 Mate Precision Tooling

Corner burrs when non-uniform

©2008 Mate Precision Tooling

Material Type Recommended

Stainless Steel 0.80mm

©2008 Mate Precision Tooling

1/8 degree per side

1 degree per side

©2008 Mate Precision Tooling

•Excessive tonnage / High tool wear / High vibrations

•Work piece distortion/stretching

©2008 Mate Precision Tooling

©2008 Mate Precision Tooling

Tool 2 Finalize the hole

©2008 Mate Precision Tooling