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2018 Tooling by Design - Angular Piercing and Punching | MetalForming Magazine

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ANGULAR PIERCING AND PUNCHING

By: Peter Ulintz

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Saturday, August 1, 2009

When a stamping is formed in an irregular shape it sometimes

becomes necessary to punch holes on an angle, especially when
punching is combined with trimming operations (Fig. 1). There is a
limit, however, to the punching angle; it should never exceed 30
deg. A common practice has been to limit piercing and punching
angles to a maximum of 15 deg. to avoid the complex guiding and
support systems needed to control punch, stripper and part
deflection. When punching angles exceed 15 deg., it generally is Fig. 1
less costly and more reliable to add an additional operation or use a cam.

Hole-size accuracy is a common problem encountered when angular punching is

employed. The punch cuts a hole opening in the part that is on a slight angle but the
part print requires the hole size to be measured normal (perpendicular) to the part
surface. As a result, the punch shape and size will differ from the final hole diameter.
Graphical methods, similar to the one shown in Fig. 2, can be used to approximate the
radii for a pierce punch at a given angle that requires the
hole to be round on the face of the part. This is
accomplished by creating a layout 10 times actual size.

Hole-size elongations can be calculated rather easily and

precisely, too. A method for calculating the hole
elongation—we’ll call this the minor-axis punch diameter
—for holes punched on an angle is shown in Fig. 3. For
Fig. 2 example: Find the minor-axis punch diameter (X+Y) if the
part print hole-diameter specification is 1.000 in., the material thickness is 0.060 in.
and the hole is being pierced at a 15-deg. angle.

Distance “X” is equivalent to the cosine of the cutting angle (15 deg.) times the punch Fig. 3
diameter (D).

Cos. 15 deg. = 0.9659

D = 1.000 in.

X = 0.9659 in.

Distance “Y” is equivalent to the sine of the cutting angle (15 deg.) times the material thickness (t)

Sine 15 deg. = 0.2588

t = 0.060 in.

Y = 0.0155 in.

Calculation Results: Minor-Axis Diameter = 0.9659 in. + 0.0155 in. = 0.9811

in.

Final Punch Size = 0.9811 in. by 1.000 in. Fig. 4

The resulting hole shape is not perfectly round. Therefore, the punch and die matrix must be keyed to ensure proper
alignment.

Cam-piercing operations may still require some of the punches to cut on an angle (Fig. 4). Again, keep the maximum
punching angle less than 15 deg., calculate the minor-axis diameter and be sure that the punch body and die
matrices are keyed. MF

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10.12.2018 Tooling by Design - Angular Piercing and Punching | MetalForming Magazine
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